Crimped fiber spunbond nonwoven webs / laminates

ABSTRACT

Nonwoven webs/nonwoven laminates for use in absorbent articles are disclosed. The nonwoven laminate includes a first nonwoven web with continuous spunbond crimped fibers and a second web joined to the first nonwoven web. A plurality of apertures extend through at least one of the first nonwoven web or the second web. The nonwoven web includes a plurality of continuous spunbond crimped fibers wherein a plurality of apertures extend through the nonwoven web.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.15/426,095, filed on Feb. 7, 2017, which is a continuation of U.S.application Ser. No. 14/933,028, filed on Nov. 5, 2015, which claims thebenefit of U.S. Provisional Application No. 62/177,405, filed Mar. 13,2015, which claims the benefit of U.S. Provisional Application No.62/076,043, filed on Nov. 6, 2014, which claims the benefit of U.S.Provisional Application No. 62/168,199, filed on May 29, 2015, which areall incorporated herein by reference.

FIELD OF THE INVENTION

The disclosure herein relates generally to a crimped fiber spunbondnonwoven web and an article incorporating the nonwoven web.

BACKGROUND OF THE INVENTION

Topsheets of disposable absorbent articles perform a valuable function.Topsheets are typically the interface between the disposable absorbentarticle and the user. As such, topsheets should be tactilely appealingto the user. Additionally, particularly in the context of hygienearticles, topsheets can mask staining caused by menses and/or urine. Ifthe topsheet does not successfully mask the staining caused bymenses/urine, the user may be left with the impression that thedisposable absorbent article did not perform well. Also, in someapplications, topsheets with the ability to acquire liquid insultsrapidly to reduce the likelihood of leakage can be desired.

There are a variety of top sheets known in the art. For example, in someconventional feminine hygiene articles, topsheets may comprise a film.Films are typically desirable because they provide good masking benefitsregarding menses/urine staining. However, without substantialprocessing, films can provide the user with a displeasing tactilesensation. And, even with the substantial processing, some usersdescribe a film topsheet as having a “plastic feel” which some usersfind displeasing. Additionally, films can sometimes leave residualliquid, e.g. menses and/or urine, in contact with the skin of the wearerwhich can exacerbate any unpleasant feelings as well as create aperception of “uncleanliness” in the mind of the user.

Other conventional feminine hygiene articles comprise nonwoventopsheets. Nonwoven topsheets can provide a soft feel to the user;however, nonwoven topsheets typically do not have good maskingcapability with regard to menses/urine stains. Unfortunately, nonwovenswhich do provide good masking properties often provide less thanadequate liquid performance.

Based on the foregoing, there is a need for a topsheet which can providea soft feel to the user while also providing good acquisition of liquidsinsults. Additionally, a topsheet which can mask menses/urine stains inconjunction with the foregoing or independently thereof, would bebeneficial.

SUMMARY OF THE INVENTION

Disclosed herein are nonwoven webs and nonwoven laminates which can beused as a topsheet of a disposable absorbent article as well as othercomponents of an absorbent article. The nonwoven webs/nonwoven laminateof the present invention, when utilized as a topsheet of a femininehygiene article, can provide a soft feel to the user and can providegood acquisition of menses/urine insults.

In some forms, nonwoven laminates of the present invention comprise afirst nonwoven web with continuous spunbond crimped fibers and a secondweb joined to the first nonwoven web. A plurality of apertures extendthrough at least one of the first nonwoven web or the second web.Additional forms include a nonwoven web comprising a plurality ofcontinuous spunbond crimped fibers, wherein a plurality of aperturesextend through the nonwoven web.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter of the present invention, itis believed that the invention can be more readily understood from thefollowing description taken in connection with the accompanyingdrawings, in which:

FIG. 1A is a schematic representation of a nonwoven laminate of thepresent invention shown in an exploded cross sectional view of thenonwoven laminate;

FIG. 1B is a schematic representation of a nonwoven laminate of thepresent invention shown in an exploded cross sectional view of thenonwoven laminate;

FIG. 2A is a schematic representation of a nonwoven laminate of thepresent invention shown in cross section;

FIG. 2B is a schematic representation of a nonwoven laminate of thepresent invention shown in cross section;

FIG. 2C is a schematic representation of a nonwoven laminate of thepresent invention shown in cross section;

FIG. 3 is a schematic representation of a nonwoven laminate of thepresent invention shown in cross section;

FIG. 4 is a schematic representation of a nonwoven laminate of thepresent invention shown in cross section;

FIG. 5 is a schematic representation of a nonwoven laminate of thepresent invention shown in cross section;

FIG. 6A is a photomicrograph of a portion of a spunbond nonwoven webshowing a top view of the spunbond nonwoven web;

FIG. 6B is a photomicrograph of a laminate comprising two layers of thenonwoven of FIG. 6A showing a side view of a cap and tuft formedtherefrom;

FIG. 6C is a photomicrograph showing a top view of the laminate of FIG.6B;

FIG. 7A top view of a spunbond crimped fiber nonwoven web;

FIG. 7B is a photomicrograph showing a side view of a nonwoven laminatecomprising the spunbond nonwoven of FIG. 6A as an upper layer and thespunbond crimped nonwoven of FIG. 7A as a lower layer, wherein thelaminate comprises a cap and tuft formed therefrom;

FIG. 7C is a photomicrograph showing a top view of the nonwoven laminateof FIG. 7B;

FIG. 8A is a photomicrograph showing a side view of a nonwoven laminatecomprising the spunbond crimped nonwoven of FIG. 7A as an upper layer,and the spunbond nonwoven of FIG. 6A as a lower layer, wherein thelaminate comprises a cap and tuft formed therefrom;

FIG. 8B is a photomicrograph showing a top view of the nonwoven laminateof FIG. 8A;

FIG. 9A is a photomicrograph showing a side view of a nonwoven laminatecomprising two layers of the crimped fiber spunbond of FIG. 7A;

FIG. 9B is a photomicrograph showing a top view of the nonwoven laminateof FIG. 9A;

FIG. 10 depicts a graph showing results of a drip test comparingnonwoven laminates with crimped fiber spunbond nonwoven layers versuslaminates with no crimped fiber spunbond nonwoven layers;

FIG. 11 depicts a graph showing results of a machine direction run-offtest comparing nonwoven laminates with crimped fiber spunbond nonwovenlayer versus laminates with no crimped fiber spunbond nonwoven layers;

FIGS. 12A and 12B depict a top view and side view, respectively, of anonwoven laminate of the present invention comprising tufts/caps;

FIGS. 13A and 13B depict a top view and side view, respectively, ofanother nonwoven laminate of the present invention comprisingtufts/caps;

FIGS. 14A and 14B depict a top view and side view, respectively, ofanother nonwoven laminate of the present invention comprisingtufts/caps;

FIGS. 15A and 15B depict a top view and side view, respectively, ofanother nonwoven laminate of the present invention comprisingtufts/caps;

FIG. 16A is a perspective view of an apparatus for forming the nonwovenlaminate of the present invention;

FIG. 16B is a schematic illustration of an apparatus for forming crimpedfiber spunbond nonwoven webs;

FIG. 16C is a photograph showing a crimped fiber;

FIG. 16D is a photograph showing a straight fiber;

FIG. 17 is a scanning electron micrograph (“SEM”) photo showing anonwoven fiber with additive that has bloomed on the surface of thefiber;

FIG. 18 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 19 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 20 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 21 is an SEM photo showing another nonwoven fiber with additivethat has bloomed on the surface of the fiber;

FIG. 22 is a photomicrograph showing other nonwoven fibers with additivethat has been applied to the fibers;

FIG. 23 is an SEM photo showing nonwoven fibers with additive that hasformed a film on the surface of the fibers;

FIG. 24 is an SEM photo showing nonwoven fibers with additive that hasformed a film and fibrils on the surface of the fibers;

FIG. 25 is an SEM photo showing nonwoven fibers with a hydrophilic meltadditive;

FIG. 26 is a top view of a feminine hygiene article, i.e. sanitarynapkin, constructed in accordance with the present invention;

FIG. 27 is a top view of an absorbent article with some layers partiallyremoved in accordance with the present disclosure;

FIG. 28 is a cross-sectional view of the absorbent article taken aboutline 20-20 of FIG. 27 in accordance with the present disclosure;

FIG. 29 is a view of the absorbent article of FIG. 28 where theabsorbent article has been at least partially loaded with fluid inaccordance with the present disclosure;

FIGS. 30-33 are photographs of portions of example nonwoven laminates inaccordance with the present disclosure;

FIG. 34 is a depiction of a coordinate system for the nonwoven laminatesof the present invention;

FIGS. 35-48 are photographs of nonwoven laminates constructed inaccordance with the present invention;

FIGS. 49-52 represent a schematic illustration of fusion bond patternsfor nonwoven laminates of the present invention;

FIGS. 53-57 are schematic illustrations of disposable absorbent articlescomprising a plurality of zones in accordance with the presentinvention;

FIGS. 58-59 represent a schematic illustrations exemplary overbondpatterns having at least some overbonds with central longitudinal axesthat are substantially parallel to a machine direction in accordancewith the present disclosure;

FIG. 60 is a photograph of a portion of a nonwoven laminate comprisingfused portions surrounding the apertures in accordance with the presentdisclosure;

FIG. 61 is a schematic representation of a stack of absorbent articleswithin a package;

FIG. 62 is a schematic illustration of a test stand for performing theTrickle Test described herein;

FIG. 63 is a schematic illustration of multiple cross sections ofbi-component fibers for use with the present invention;

FIG. 64 is a graph depicting stress stain curves for a spunbond nonwovenweb and two crimped fiber spunbond nonwoven webs;

FIGS. 65-74 are photographs of patterned apertured webs in accordancewith the present disclosure;

FIGS. 75-81 are illustrations showing overbonds, patterned adhesive andcombination of overbonds and patterned adhesive, respectively; and

FIG. 82 is an exemplary cross section of a laminate structureconstructed in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The term “fibrils” refers to projections, elongate projections, bumpsthat extend outwardly from a surface or generally radially outwardlyfrom an outer surface of a fiber. In some instances, the projections,elongate projections, or bumps may extend radially outwardly relative toa longitudinal axis of the fiber. Radially outwardly means in the rangeof 1 to 89 degrees relative to the longitudinal axis. In still otherinstances, the projections, elongate projections, or bumps may extendradially outwardly from a surface of a fiber at least in a longitudinalcentral third of the fiber. The projections, elongate projections, orbumps comprise, consist of, or consist essentially of (e.g., 51% to 100%or 51% to 99%), melt additives. The projections, elongate projections,or bumps grow from the fibers post-nonwoven substrate formation onlyafter a time period (e.g., 6-100 hours) under ambient conditions.Fibrils can be viewed using an SEM at, at least 1,000 timesmagnification.

As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. The basis weight of nonwovenfabrics is usually expressed in grams per square meter (gsm). The basisweight of a nonwoven web/laminate is the combined basis weight of theconstituent layers and any other added components. Fiber diameters areusually expressed in microns; fiber size can also be expressed indenier, which is a unit of weight per length of fiber.

As used herein “philic” and “phobic” have meanings as well establishedin the art with respect to the contact angle of a referenced liquid onthe surface of a material. Thus, a material having a liquid contactangle of greater than about 75 degrees is considered phobic, and amaterial having a liquid contact angle of less than about 75 degrees isconsidered philic.

As used herein, “spunbond fibers” refers to small diameter fibers whichare formed by extruding molten thermoplastic material as filaments froma plurality of fine, usually circular capillaries of a spinneret withthe diameter of the extruded filaments then being rapidly reduced.Spunbond fibers are generally not tacky when they are deposited on acollecting surface. Spunbond fibers are generally continuous and haveaverage diameters (from a sample of at least 10) larger than 7 microns,and more particularly, between about 8 and 40 microns.

As used herein, “spunbond crimped fibers” refers to bi-component fiberswhich may be configured in a side-by-side, core-eccentric sheath orother suitable configuration. The selection of suitable resincombinations and bi-component fiber configuration can lead to a helicalcrimp or curl generated in the fibers. The crimp may occur spontaneouslyduring the spinning or laydown process, on its own after web formation.In some instances, the webs may require an additional step (e.g. heatingor mechanical deformation) to induce the fibers to crimp.

By “substantially randomly oriented” it is meant that, due to processingconditions of a nonwoven layer, there may be a higher amount of fibersoriented in the machine direction (MD) than the cross direction (CD), orvice-versa.

As used herein, the term “absorbent article”, refers to devices whichabsorb and contain body exudates, and, more specifically, refers todevices which are placed against or in proximity to the body of thewearer to absorb and contain the various bodily exudates discharged fromthe body. The term absorbent article includes, but is not limited to,diapers, pants, training pants, adult incontinence products, sanitarynapkins, tampons, wipes, and liners. The term “absorbent article” alsoencompasses cleaning or dusting pads or substrates that have someabsorbency.

The present invention pertains to crimped fiber spunbond nonwoven websthat are suitable for use in a disposable absorbent article. The presentinvention also pertains to nonwoven laminates which comprise at leastone layer which is a crimped fiber spunbond nonwoven web. As discussedhereafter, the crimped fiber spunbond nonwoven webs/nonwoven laminatesof the present invention may comprise caps and/or tufts or otherout-of-plane deformations which provide a softness benefit, a maskingbenefit and/or a fluid handling benefit. Optionally, the crimped fiberspunbond nonwoven webs or other webs of a nonwoven laminate of thepresent invention may comprise an additive either applied post formationand/or blended into the fiber (discussed hereafter) so that the additiveis present during the formation of the constituent fibers. The inventorshave found that these additives can provide masking benefits such thatmenses/urine stains are less visible to a user of the disposableabsorbent article. Additionally, the inventors have found that theadditives can provide the treated web with better draining capabilitysuch that less fluid sticks to the fibers and/or interstices betweenintersecting fibers. This draining capability can also result in bettermasking of urine/menses stains. Also, the inventors have found that theadditives can provide the crimped fiber spunbond nonwoven web or otherwebs of a nonwoven laminate of the present invention with improvedacquisition time for liquid insults which reduces the likelihood ofleaking. Some suitable additives contemplated are with regard tohydrophobicity, hydrophilicity, softness, reduction of coefficient offriction, or the like. Some suitable additives are discussed herein.

Nonwoven Webs/Laminates

A nonwoven web constructed in accordance with the present inventioncomprises spunbond crimped fibers. In other forms of the presentinvention, crimped fiber spunbond webs of the present invention maycomprise multiple substrates. For example, a crimped fiber spunbond webof the present invention may be made via a spunbond process comprisingmultiple spinbeams. In such forms, a first substrate created from afirst spinbeam may comprise continuous spunbond fibers while a secondsubstrate created from a second spinbeam may comprise continuous crimpedspunbond fibers. The method of making the crimped fiber spunbond websand laminates of the present invention is discussed in additional detailhereafter.

Laminates constructed in accordance with the present invention maycomprise at least two webs (layers) at least one of which is a crimpedfiber spunbond nonwoven web. In other forms, the laminate may comprise afilm web and a crimped fiber spunbond nonwoven web. In other forms, thelaminate may comprise a crimped fiber spunbond nonwoven web and anothernonwoven web.

The crimped fiber spunbond nonwoven webs and nonwoven laminates of thepresent invention have a machine direction (MD) (perpendicular to theplane of the sheets showing FIGS. 1A, 1B, and 2A-2C), a cross machinedirection (CD), and a Z direction, as is commonly known in the art ofweb manufacture. Each of the nonwoven laminates of the present inventioncomprises at least two nonwoven webs which are referred to herein asgenerally planar, two-dimensional webs. Crimped fiber spunbond nonwovenwebs are also referred to herein as generally planar, two-dimensionalwebs.

FIG. 1A shows an exploded cross sectional view of a nonwoven laminate100 of the present invention. The nonwoven laminate 100 comprises afirst layer 110 having a first surface 115 and a second surface 120,each of which are generally planar. The nonwoven laminate 100 furthercomprises a second layer 150A having a first surface 155 and a secondsurface 160 each of which are generally planar. The first surfaces 115and 155 of the first layer 110 and the second layer 150, respectively,can be body-facing surfaces and the second surfaces 120 and 160 of thefirst layer 110 and the second layer 150A, respectively, can begarment-facing surfaces.

At least one of the first layer or second layer comprises a crimpedfiber spunbond nonwoven web. For example, the first layer may comprisespunbond crimped fibers while the second layer does not comprisespunbond crimped fibers. In another example, the first layer may notcomprise spunbond crimped fibers while the second layer comprisesspunbond crimped fibers. In yet another example, both the first layerand the second layer may comprise spunbond crimped fibers.

The first layer 110 may comprise a first plurality of apertures 125 thatextend through the first layer 110 from the first surface 115 to thesecond surface 120. As shown, the second layer 150, in some forms, maynot include apertures. However, as shown in FIG. 1B, the second layer150 may comprise a second plurality of apertures 165. As shown, thefirst plurality of apertures 125 and the second plurality of apertures165 may be substantially aligned.

Substantially aligned, in the context of the apertures herein, meansthat the majority of the first plurality of apertures, i.e. at least51%, comprise a reciprocal aperture in the second layer 150, and ofthose apertures in the first layer 110 comprising a reciprocal aperturein the second layer 150, at least 51% of the open area of each of thoseapertures in the first layer 110 corresponds to open area of an aperturein the second layer 150. In some forms, the first plurality of apertures125 and the second plurality of apertures 165 are createdcontemporaneously and may be coterminous. Still in other forms, thefirst plurality of apertures 165 and the second plurality of apertures165 may be produced separately such that a portion of the second layer150 may be exposed through at least one of the first plurality ofapertures 150 and vice versa. Some suitable aperturing processes arediscussed hereafter.

The first layer 110 and the second layers 150, may be joined about theperiphery of each of the first plurality of apertures 125. For example,for those processes where apertures are created by melting fibers of thefirst layer 110 typically an aperture periphery is formed. Additionallyduring the melting, the melted fiber material can form bonds withsurrounding fibers including the fibers of the second layer 150. Thesame can occur where both the first layer 110 and the second layer 150comprise apertures. In such forms, the first layer 110 and the secondlayer 150 are attached to one another about at least a portion of theperiphery of each of the second plurality of apertures 165. In someforms, the first layer 110 and the second layer 150 are attached to oneanother about at least a portion of the periphery of each of the firstplurality of apertures 125. One of the benefits of utilizing a crimpedfiber spunbond nonwoven web is that the melted fibers are lessnoticeable with the higher caliper of the crimped fiber spunbondnonwoven web.

The nonwoven laminate 100 of FIGS. 1A and 1B can provide a soft feel toa user of an absorbent article incorporating the nonwoven laminate 100as the topsheet of the absorbent article. An additional softnessbenefit, masking benefit and/or fluid handling benefit can be gained bythe out-of-plane deformations described with regard to FIGS. 2A-2C.

With regard to FIG. 2A, a schematic representation of the nonwovenlaminate 100 constructed in accordance with the present invention isshown. In some forms of the present invention, the first layer 110 mayadditionally comprise a first plurality of discontinuities 235 in thesecond surface 120 of the first layer 110. The first plurality ofdiscontinuities 235 are formed when localized areas of constituentmaterial of the first layer 110 are urged in the Z-direction such thatthe constituent material of the first layer 110 is disposed superjacentto the first surface 115 of the first layer 110. The disposition of theconstituent material, may, in some forms, create an out-of-planedeformation, e.g. a cap 230. The first layer 110 may comprise aplurality of caps 230 positioned above the first surface 115. Each ofthe plurality of caps 230 can partially overlie at least one of thefirst plurality of discontinuities 235. For example, a first cap may atleast partially overlay a first discontinuity, and a second cap may atleast partially overlay a second discontinuity and so on. Caps 230 arediscussed in additional detail hereafter.

Similarly, the second surface 160 of the second layer 150 may comprise asecond plurality of discontinuities 275. The second plurality ofdiscontinuities 275 can be formed as provided above with regard to thefirst plurality of discontinuities 235 in the first layer 110. Namely,localized areas of constituent material of the second layer 150 areurged in the Z-direction such that these localized areas of constituentmaterial are disposed superjacent to the first surface 155 of the secondlayer 150. In some forms, this Z-direction urging also forces theconstituent material of the second layer 150 to extend through the firstplurality of discontinuities 235 in the second surface 120 of the firstlayer 110. The urging of the constituent material of the second layer150 can also form an out-of-plane deformation, e.g. a tuft 270. Eachtuft 270 may extend through a corresponding discontinuity 235 in thefirst layer 110.

As shown in FIG. 2B, the first layer 110 may in some forms comprise thefirst plurality of apertures 125 in the first layer 110. Similarly, withregard to FIG. 2C, the nonwoven laminate 100 may comprise the secondlayer 150 which comprises the second plurality of apertures 165.Additional forms are contemplated where the second layer 150 comprisesapertures in the absence of apertures in the first layer 110.

Additional arrangements of caps and/or tufts are provided with respectto FIGS. 3-5. With regard to FIG. 3, the first layer 110, in some formsmay not form a cap with the Z-direction urging described heretofore. Insuch forms, the constituent material, e.g. fibers, of the first layer110 may break during the urging which allows the tuft 270 to be exposedthrough the first layer 110. In other forms, regarding FIG. 4, thenonwoven laminate 100 may comprise a first plurality of discontinuities435. The first plurality of discontinuities 435 are formed whenlocalized areas of constituent fibers of the first layer 110 are urgedin the negative Z-direction such that the constituent material aredisposed subjacent to the first surface 115 of the first layer 110thereby forming out-of-plane deformations, e.g. tufts 470. In someforms, the tufts 470 may extend beyond the second surface 160 of thesecond layer 150 such that at least a portion of the tuft 470 issubjacent to the second surface 160.

The second layer 150 may comprise a second plurality of discontinuities475. As shown, each of the plurality of tufts 470 may extend througheach of the second plurality of discontinuities 475. The secondplurality of discontinuities 475 may be created when localized areas ofconstituent material, e.g. fibers, of the second layer 150 are urged inthe negative Z-direction such that the constituent material in thelocalized areas are disposed subjacent to the first surface 155 of thesecond layer 150. However, instead of forming a cap 230 (shown in FIGS.2A-2C), the urging in the negative Z-direction of the constituentmaterial of the second layer 150 may be such that a plurality offibers/material break thereby forming the second plurality ofdiscontinuities 475. Each tuft 470 extends through a correspondingdiscontinuity in the second layer 450. As shown, tufts 470 may beuncovered by a corresponding cap formed by the constituent fibers of thesecond layer 450.

With regard to FIG. 5, the disposition of the constituentfibers/material of the second layer 150 may form an out-of-planedeformation, e.g. a cap 530. The caps 530 may extend below the secondsurface 160. Each of the plurality of caps 530 can partially underlie atleast one of the second plurality of discontinuities 475. For example, afirst cap at least partially underlies a first discontinuity, and asecond cap at least partially underlies a second discontinuity and soon.

Each of the first layers and second layers described herein may comprisesubstantially randomly oriented fibers. For those nonwoven laminates 100described heretofore which comprise both tufts and caps, tufts need notnecessarily be covered by a corresponding cap. For example, in somenonwoven laminates 100, at least 50% of tufts comprise a correspondingcap which substantially covers their respective tuft. In other examples,more than 75% of tufts of a nonwoven laminate 100 may comprise acorresponding cap. By “substantially covers” it is meant that more than51% of the exterior surface of the tuft is covered by a correspondingcap.

Other exemplary laminates in accordance with the present inventioninclude a first layer comprising a film and a second layer whichcomprises a crimped fiber spunbond web. In another example, the firstlayer may comprise a crimped fiber spunbond nonwoven web while thesecond layer comprises a film. In yet another example the first layermay comprise a crimped fiber spunbond nonwoven web and the second layermay comprise a nonwoven web. In such forms, the second layer maycomprise a crimped fiber spunbond nonwoven web. Or, the second layer maycomprise a nonwoven web which is spunbond sans spunbond crimped fibers.Or, the second layer may comprise a nonwoven web which is carded,meltblown, etc. The out-of-plane deformations described herein may beprovided on any of the laminates of the present invention describedherein.

Additionally, the inventors have found that when spunbond crimped fibersare utilized, the out-of-plane deformations described herein take onvery different configurations. The configuration differences arehighlighted with regard to FIGS. 6A-6C through FIG. 9B.

FIGS. 6A-6C illustrate tufts which may be formed with nonwoven layerscomprising extensible fibers. Shown in FIG. 6A is a spunbond nonwovenweb 605—no spunbond crimped fibers. FIG. 6B shows a nonwoven laminate610 comprising two layers of the spunbond nonwoven web shown in FIG.6A—again, no spunbond crimped fibers. Each of the layers comprisesbi-component, extensible fibers but neither comprises crimped fiberspunbond nonwoven webs. As shown, the laminate 610 comprises a pluralityof caps 630 and tufts 670.

Regarding FIG. 6C, caps and tufts alike can comprise a plurality oflooped fibers that are substantially aligned such that each of the capsand tufts have a distinct linear orientation and a longitudinal axis L.By “looped” fibers it is meant to refer to fibers of the tufts and/orcaps that are integral with and begin and end in the nonwoven layer inwhich they begin but extend generally outwardly in the Z-direction (ornegative Z-direction) from the first surface or second surface of therespective layer. By “aligned”, it is meant that looped fibers are allgenerally oriented such that, if viewed in plan view, each of the loopedfibers has a significant vector component parallel to a transverse axisand can have a major vector component parallel to the transverse axis.The transverse axis T is generally orthogonal to longitudinal axis inthe MD-CD plane and the longitudinal axis is generally parallel to theMD.

As described below, another characteristic of tufts/caps shown in FIGS.6A-6C—formed with extensible non-crimped fibers—can be their generallyopen structure characterized by open void area 633 defined interiorly ofthe cap 630 and/or tuft 670 cap 630 and/or tuft 670. The term “voidarea” is not meant to refer to an area completely free of any fibers.The void area 633 of caps 630 may comprise a first void space openingand a second void space opening. Rather, the term is meant as a generaldescription of the general appearance of caps 630. Therefore, it may bethat in some caps 630 a non-looped fiber or a plurality of loosenon-looped fibers may be present in the void area 633. By “open” voidarea is meant that the two longitudinal ends of cap 630 are generallyopen and free of fibers, such that cap 630 can form something like a“tunnel” structure in an uncompressed state, as shown in FIGS. 6A-6C.The general shape of the tufts may be similar to that of the cap 630;and in some forms, the nonwoven may not comprise a corresponding cap forthe tuft.

Looped fibers and/or non-looped fibers of cap 630 can originate andextend from either the first surface or the second surface of the firstlayer. Of course the looped fibers or non-looped fibers of cap 630 canalso extend from an interior of first layer. In general, with regard tocaps 630, the looped fibers and non-looped fibers comprise fibers thatare integral with and extend from the fibers of the first layer.

The extension and/or urging of looped fibers and non-looped fibers asshown in FIGS. 6A-6C, can be accompanied by a general reduction in fibercross sectional dimension (e.g., diameter for round fibers) due toplastic deformation of the fibers and Poisson's ratio effects.Therefore, the aligned looped fibers of caps and/or tufts 670 can havean average fiber diameter less than the average fiber diameter of thefibers of the layer from which the tuft and/or cap emanates.

In contrast to the caps 630 and tufts 670 shown in FIGS. 6A-6C, nonwovenlaminates of the present invention comprising crimped fiber spunbondnonwoven webs form very different out-of-plane deformations than thoseshown in FIGS. 6A-6C. Shown in FIGS. 7B-9B are nonwoven laminatesconstructed utilizing crimped fiber spunbond nonwoven webs. The nonwovenlaminates shown in FIGS. 7B-9B comprise at least one crimped fiberspunbond nonwoven web.

A nonwoven laminate 710 is shown in FIGS. 7B-7C. The nonwoven laminate710 comprises a spunbond nonwoven web, e.g. 605 (shown in FIG. 6A) as anupper layer of the nonwoven laminate 710 and a crimped fiber spunbondnonwoven web 705 (shown in FIG. 7A) as a lower layer of the nonwovenlaminate 710. The nonwoven laminate 710 comprises a tuft 770 formed fromthe constituent fibers of the crimped fiber spunbond nonwoven web 705and a corresponding cap 730 formed from the constituent fibers of thespunbond nonwoven web 605. As shown, caps 730 and/or tufts 770 may havea similar shape to caps 630 and/or tufts 670. However, as shown, tufts770, are substantially filled with looped fibers and/or non-loopedfibers. Additionally notwithstanding the fact that the conventionalspunbond nonwoven layer is the upper layer in the laminate 710, thelooped fibers of the resultant out-of-plane deformation of FIG. 7Cappear more random as opposed to being aligned with regard to thetransverse axis T. The caps 730 can be configured similarly to caps 630except as otherwise noted above. And, in contrast to the tufts 670,shown in FIGS. 6A-6C, it has been found that for the tufts 770, theconstituent fiber is quite often uncoiled from its curly state ratherthan stretched and thinned.

With regard to FIGS. 8A and 8B, nonwoven laminate 810 is the nonwovenlaminate of FIGS. 7B-7C inverted. The crimped fiber spunbond nonwovenweb 705 (shown in FIG. 7A) is utilized as an upper layer of the nonwovenlaminate 810. The spunbond nonwoven web 605 (shown in FIG. 6A) isutilized as a lower layer of the nonwoven laminate 810. Much like theside view of nonwoven laminate 710 (shown in FIG. 7B) the side view ofnonwoven laminate 810 reveals a cap 830 which is filled. And much likethe nonwoven laminate 710 (shown in FIG. 7B), the structures formed onthe nonwoven laminate 810 comprise fibers which are more random andcurly as opposed to being aligned with regard to the transverse axis T.

With regard to FIGS. 9A and 9B, a nonwoven laminate 910 shown comprisescrimped fiber spunbond nonwoven webs, e.g. 705 (shown in FIG. 7A) asboth upper and lower layers of the nonwoven laminate 910. In the sideview shown in FIG. 9A, a tuft 970 and corresponding cap 930 are shown.Each is filled with the constituent fibers of their respective spunbondcrimped nonwoven layers. And similar to the top views shown in FIGS. 7Cand 8, the top view of the nonwoven laminate 910 shown in FIG. 9Bdepicts the constituent fibers which are more randomly oriented andcurly compared to those shown in FIG. 6C.

The filled tufts 770 and 970 can be beneficial for those forms where thesecond layer comprises tufts 770, 970 which extend through the firstlayer. For example, if the first nonwoven does not include acorresponding cap over the tuft 770 or 970 liquid insults can have easyaccess to the material of the tuft 770, 970. And, if the material of thetufts 770 or 970 is hydrophilic either from a fiber standpoint and/oradditive standpoint, the filled tuft 770, 970 will provide additionalsurface area for the liquid to contact. Similarly, even in those formswhere a corresponding cap exists emanating from the first layer, thetuft 770, 970 may still provide great liquid handling properties. Forexample, as described with regard to FIG. 6B, the tuft 670 may comprisea first void opening 651 and a second void opening 652 exposing the voidarea 633. Caps constructed with non-crimped fibers may be similarlyconfigured such that there are corresponding openings allowing fluidaccess to the underlying tufts 770, 970. Accordingly, the tuft 770, 970may still have very good access to the liquid insults via the voidopenings in the cap. Similarly, caps 830 can provide these fluidhandling benefits as well.

Caps of nonwoven laminates of the present invention are thought to maskor partially mask fluid that is collected by the nonwoven laminateremaining in the capillaries between fibers of the tufts. Such nonwovenlaminates employed in an absorbent article such as a wipe, a sanitarynapkin, a tampon, or a diaper can be appealing to the user (orcaregiver) in that potentially unsightly fluids retained in thecapillaries between fibers of the tufts will be obscured or partiallyobscured from the viewer. The tufts/caps may cover or partially coverinterstices in which fluids can be held. Such a feature can make thenonwoven laminate appear less soiled. Additionally, because the nonwovenlaminates of the present invention comprises at least one crimped fiberspunbond nonwoven web, the resultant nonwoven laminate has a highercaliper for a given basis weight. This higher caliper in turn deliversconsumer benefits of comfort due to cushiony softness, faster absorbencydue to higher permeability, and improved masking. Additional benefitsmay include less redmarking, higher breathability and resiliency.

A crimped fiber spunbond nonwoven web may provide similar benefits. Forexample, tufts created in the crimped fiber spunbond nonwoven web couldprovide a masking benefit even if utilized independently with noadditional layers.

Additionally, the incorporation of a crimped fiber spunbond nonwoven webinto a laminate or an absorbent article provides many additionaladvantages. For example, for the creations of many out-of-planedeformations, constituent materials that are not extensible generallybreak or tear when subjected to such processes. However, constituentmaterials for crimped fiber spunbond nonwoven webs do not require suchextensibility. Specifically, during processing for out-of-planedeformations, rather than stretching and thinning fibers, fibers of thecrimped fiber spunbond nonwovens tend to uncurl. As such, materialswhich would ordinarily not be suited for out-of-plane deformationprocessing, may be suitable for such processing if configured in acrimped fiber spunbond nonwoven web. Suitable materials for the crimpedfiber spunbond nonwoven webs of the present invention are discussedhereafter. Additionally, crimped fiber spunbond nonwoven webs generallyexhibit better elastic recovery from out-of-plane deformation processingthan conventional bi-component fibers in spunbond webs.

Additionally, some crimped fiber spunbond nonwoven webs may comprisebetter tensile elongation than spunbond nonwoven webs. In one specificexample, crimped fiber spunbond nonwoven webs comprisingpolypropylene/polypropylene bi-component fibers may exhibit a highertensile elongation than a spunbond nonwoven comprising polypropylenemonocomponent fibers. A graph depicted in FIG. 64 shows the differencein tensile elongation between an exemplary crimped fiber spunbondnonwoven web and sponbond nonwoven webs.

As shown, spunbond nonwoven web 6400 exhibited lower tensile elongationthan did the crimped fiber spunbond nonwoven webs 6410 and 6420. Thespunbond nonwoven web 6400 was a 30 gsm spunbond nonwoven comprising 2.5denier per filament monocomponent fibers comprising 100% Lyondell BasellHP561R. This spunbonded nonwoven web 6400 was calendar bonded to an 18percent bond area.

The crimped fiber spunbond nonwoven web 6410 was a 26 gsm nonwoven webcomprising 2.6 denier per filament bi-component fibers which were a60/40 side-by-side configured polypropylene. Where the first componentof the bi-component fiber was a polypropylene from Lyondell BasellHP561R and the second component was also a polypropylene from LyondellBasell HP552R. The first component further comprised 17% TechmerPPM17000 High Load hydrophobic masterbatch and 1% TiO₂ masterbatch. Thesecond component comprised 14% Techmer PPM17000 High Load hydrophobicmasterbatch. The crimped fiber spunbonded nonwoven web 6410 was calendarbonded to an 18 percent bond area.

The crimped fiber spunbonded nonwoven web 6420 was a 30 gsm nonwoven webwhich comprised fibers having 2.6 denier per filament bi-componentfibers. The bi-component fibers were configured in a 60/40 side-by-sidearrangement. A first component comprised Lyondell Basell HP561Rpolypropylene and a second component comprised Lyondell Basell HP552 Rpolypropylene. The first and second components both additionallycomprised 16% Techmer PPM17000 High Load Hydrophobic masterbatch. Thesecond component additionally comprised 1.5% TiO₂. The crimped fiberspunbonded nonwoven web 6420 was calendar bonded to a 12 percent bondarea.

Additionally, tensile strength for spunbond crimped fiber nonwoven websmay be greater than the tensile strength exhibited by carded crimpedfiber nonwoven webs. In general, the spunbond process, including thespunbond crimped fiber process, utilizes continuous fibers while thecarded spunbond fiber process utilizes staple fibers—fixed length notcontinuous. Still another distinction between crimped fiber spunbondnonwoven webs and crimped fiber carded nonwoven webs is that a tensilestrength ratio between the MD and CD is generally more balanced forcrimped fiber spunbond nonwoven webs. In general, crimped fiber cardednonwoven webs have a much higher tensile strength in the MD as thefibers are typically combed to be aligned in the MD direction.

Additional benefits of utilizing crimped fiber spunbond nonwoven webs isthat in some forms, particularly where the fibers comprise bi-componentpolypropylene/polypropylene, better bond strength can be achieved whichmakes this crimped fiber spunbond nonwoven web more abrasion resistant.

Even still more additional benefits of crimped fiber spunbond nonwovenwebs include compatibility with like chemistries. For example, crimpedfiber spunbond nonwoven webs comprising polypropylene/polypropylenebi-component fibers may be thermally joined (bonded) to subjacentmaterials in a disposable absorbent article which are polypropylenebased. Also, the cost associated with polypropylene/polypropylene fiberscan be less than the cost associated with other bi-component fibers.And, polypropylene/polypropylene fibers or fibers comprising twodifferent polyesters may be recyclable versus bi-component fiberscomprising polyethylene/polypropylene.

Regarding permeability, nonwoven laminates of the present invention,which include a crimped fiber spunbond nonwoven layer, have a higherpermeability than nonwoven laminates which do not comprise a crimpedfiber spunbond nonwoven layer. This is illustrated in Table 2. Table 2also includes data regarding individual nonwoven webs.

Examples

All Crimped Fiber Spunbond (“CFSB”) nonwoven web samples below are 25gsm webs comprised of fibers 2.6 denier per filament, side-by-sidepolypropylene/polypropylene, using Lyondell Basell HP561R in the firstcomponent and Lyondell Basell HP552R in the second component. Bothcomponents additionally comprise 1% of TiO₂ masterbatch (MBWhite009).The CFSB nonwoven web samples were produced by Reifenhauser GmbH locatedin Troisdorf, Germany.

-   CFSB1: In addition to above description, CFSB1 had a 60/40 ratio of    polypropylene components. Both components additionally comprised 16%    Techmer PPM17000 High Load Hydrophobic masterbatch. The nonwoven    layer was calendar bonded with a dot bond pattern having 12% bond    area.-   CFSB2: In addition to the above description, CFSB2 has a 70/30 ratio    of polypropylene components. The nonwoven layer was calendar bonded    with a dot bond pattern having 12% bond area and coated with 0.4% by    weight Silastol PHP26 surfactant made by Schill & Seilacher,    Germany.-   CFSB3: In addition to the above description, CFSB3 has a 70/30 ratio    of polypropylene components. The nonwoven layer is calendar bonded    with a diamond bond pattern having 14.6% bond area.

All Spunbond (“SB”) samples below are spunbond nonwoven webs comprisedof polyethylene/polypropylene sheath/core bi-component fibers.

-   SB1: In addition to the above description, SB1 is a 25 gsm nonwoven    web comprising fibers which are 2.5 denier per filament with 30/70    polyethylene/polypropylene ratio from Fibertex Personal Care in    Nilai, Malaysia. The fibers additionally comprise 17% of Techmer PPM    17000 High Load Hydrophobic masterbatch in the sheath.-   SB2: In addition to the above description, SB2 is a 28 gsm nonwoven    web comprising fibers which are 2.8 denier per filament with 50/50    polyethylene/polypropylene ratio purchased from Fitesa in Washougal,    Wash. The web has been coated with 0.45% by weight of Silastol PST-N    surfactant available from Schill & Seilacher, Germany.-   SB3: In addition to the above description, SB3 is a 25 gsm nonwoven    web comprising fibers which are 2.5 denier per filament with 30/70    polyethylene/polypropylene ratio from Pegas Nonwovens s.r.o., in    Znojmo, Czech Republic.

All laminates below are comprised of two layers of nonwoven webs listedabove.

TABLE 1 Upper Layer Lower layer Formation Laminate 1 CFSB1 CFSB2Tufts/Caps Laminate 2 SB1 SB2 Tufts/Caps Laminate 3 SB1 CFSB2 Tufts/CapsLaminate 4 CFSB3 CFSB2 Apertures (both layers bonded around perimeter)Laminate 5 SB3 SB2 Apertures (both layers bonded around perimeter)

For those nonwoven webs comprising Techmer PPM 17000 High LoadHydrophobic masterbatch, a fibril structure on the fiber surface wasformed (discussed hereafter). The masterbatch comprised about 60 percentby weight polyethylene and about 40 percent by weight glyceroltri-stearate.

TABLE 2 Through-plane permeability Material CHH (Darcy) CFSB1 39 CFSB278 SB1 19 SB2 52 Laminate 1: CFSB1/CFSB2 196 Laminate 2: SB1/SB2 65Laminate 3: SB1/CFSB2 104

As shown in Table 2, CFSB1 had a higher permeability than SB1, and CFSB2had a higher permeability than the SB2—comparing philic to philicadditive and phobic to phobic additive. Without wishing to be bound bytheory, it is believed that crimped fiber spunbond nonwoven webscomprise an open structure in general. It is further believed that dueto this open structure, the crimped fiber spunbond nonwoven webs and/ornonwoven laminates formed therefrom have a higher permeability. Higherpermeability is believed to aid in transporting fluid faster through thenonwoven laminate. So, for those executions where Laminate 1 or Laminate3 is utilized as a topsheet, the higher permeability would be believedto provide fluid handling benefits for the articles into which suchtopsheets were incorporated.

Additional fluid handling benefits are demonstrated in Table 3. As shownin Table 3, two nonwoven webs were compared with regard to theirrespective desorption potential.

TABLE 3 eCWP Drainage Median desorption Potential pressure MaterialSample No. (micro J/g fluid) (cm H₂O) CFSB2 1793 13.3 SB2 2251 17.8

As shown in Table 3, CFSB2 required less energy to drain than SB2. It isbelieved that for those configurations where a crimped fiber spunbondnonwoven web is disposed adjacent an absorbent core, the absorbent coremay more easily drain the crimped fiber spunbond nonwoven web than thespunbond nonwoven web.

Additional benefits of crimped fiber spunbonds include fluidacquisition. FIG. 10 shows a comparison between various laminates.Laminate 3 versus Laminate 2 is shown. Recall that Laminate 3 comprisesa crimped fiber spunbond nonwoven web as a lower layer and a spunbondnonwoven web as an upper layer while Laminate 2 comprises a spunbondnonwoven web as an upper and lower layer. The graph shown in FIG. 10demonstrates that Laminate 3 (spunbond nonwoven web upper layer andcrimped fiber spunbond nonwoven web lower layer) acquires liquid insultsbetter than Laminate 2 (spunbond nonwoven web upper and lower layers).

Recall that as shown in FIGS. 7A-7C, the tufts formed by crimped fiberspunbond nonwoven webs are filled to a much larger extent than tuftsformed by conventional spunbond nonwoven webs. It is believed that thefilled tufts and lower web density created by the crimped fiber spunbondnonwoven webs can provide fluid insults better access to the fibers ofthe crimped fiber spunbond nonwoven web which in turn can lead to betterfluid acquisition.

Regarding FIG. 11, crimped fiber spunbond nonwoven webs can similarlyprovide better resistance to fluid runoff. The graph of FIG. 11 shows acomparison of fluid runoff for a pair of apertured nonwoven laminates.As described in Table 1, Laminate 4 comprises CFSB3 as an upper layerand CFSB 2 as a lower layer. Laminate 5 comprises SB3 as an upper layerand SB2 as a lower layer. While each of the laminates comprised tuftsand/or caps, the fluid runoff test was performed in an area of thelaminates which was apertured and absent out-of-plane deformations.

As shown in the graph of FIG. 11, Laminate 4 has less runoff thanLaminate 5. Without wishing to be bound by theory, it is believed thatcrimped fiber spunbond nonwoven webs offer more resistance to fluid flowdue to their lofty nature. This increased resistance helps to reducefluid runoff which should result in less soiling of the skin of a wearerduring use.

Regarding the tufts discussed heretofore, tufts may be spaced apart fromadjacent tufts, and similarly caps may be spaced apart from adjacentcaps. Each of the spaced apart tufts and/or spaced apart caps havegenerally parallel longitudinal axes L. The number of tufts and/or capsper unit area of a nonwoven laminate of the present invention, i.e., thearea density of tufts and/or caps, can be varied from one tuft per unitarea, e.g., square centimeter to as high as 100 tufts per squarecentimeter or similarly with regard to caps. There can be at least 10,or at least 20 tufts and/or caps per square centimeter, depending on theend use. In general, the area density need not be uniform across theentire area of nonwoven laminates of the present invention, and, in someembodiments, tufts and/or caps can be only in certain regions ofnonwoven laminates of the present invention, such as in regions havingpredetermined shapes, such as lines, stripes, bands, circles, and thelike.

As noted previously, the first layer and/or second layer may compriseapertures as disclosed herein and/or out-of-plane deformations, e.g.tufts, as disclosed herein. Some suitable examples of additionalout-of-plane deformations for use in conjunction with the crimped fiberspunbond nonwoven webs/laminates of the present invention, includeridges, grooves, and/or valleys. Methods of forming ridges and/orgrooves are discussed further in U.S. Pat. No. 7,954,213; U.S. PatentApplication Publication Nos. US2012/0045620; US2012/0196091;US2012/0321839; US2013/0022784; and US2013/0017370; and PCT PatentApplication Publication Nos. WO2011/125893; and WO2012/137553. Othersuitable processes for producing ridges and/or recesses and theresulting structures are disclosed in U.S. Pat. Nos. 6,458,447;7,270,861; 8,502,013; 7,625,363; 8,450,557; and 7,741,235. Additionalsuitable processes and structures are described in US Patent ApplicationPublication Nos. US2003/018741; US2009/0240222; US20120141742;US2013/013732; US2013/0165883; US2013/0158497; US2013/0280481;US2013/0184665; US2013/0178815; and US2013/0230236700. Still additionalsuitable processes and structures are described with regard to PCTPatent Application Publication Nos. WO2008/156075; WO2010/055699;WO2013/018846; WO2013/047890; and WO2013/157365.

Additional out-of-plane deformations include embossing. Embossing ofabsorbent articles generally results in thinned out areas in theabsorbent article. Embossing, similar to fusion bonding, involves themanipulation of material in a first layer and a second layer in thepositive and/or negative Z-direction. Generally, embossing does notresult in the fusion of layers. Unlike fusion bonds, embossing typicallyresults in macro depressions in an absorbent article. Embossing isfurther discussed in U.S. Pat. Nos. 8,496,775 and 8,491,742.

Precursor Materials

The crimped fiber spunbond nonwoven webs/laminates of the presentinvention begin with constituent fibers. As noted previously, fornonwoven laminates of the present invention, at least one web is acrimped fiber spunbond nonwoven web. The plurality of randomly orientedfibers of the crimped fiber spunbond nonwoven webs/laminates maycomprise any suitable thermoplastic polymer. Some suitable thermoplasticpolymers, as used in the disclosed compositions, are polymers that meltand then, upon cooling, crystallize or harden, but can be re-melted uponfurther heating. Suitable thermoplastic polymers used herein have amelting temperature (also referred to as solidification temperature)from about 60° C. to about 300° C., from about 80° C. to about 250° C.,or from 100° C. to 215° C. And, the molecular weight of thethermoplastic polymer should be sufficiently high to enable entanglementbetween polymer molecules and yet low enough to be melt spinnable.

The thermoplastic polymers can be derived any suitable materialincluding renewable resources (including bio-based and recycledmaterials), fossil minerals and oils, and/or biodegradeable materials.Some suitable examples of thermoplastic polymers include polyolefins,polyesters, polyamides, copolymers thereof, and combinations thereof.Some exemplary polyolefins include polyethylene or copolymers thereof,including low density, high density, linear low density, or ultra-lowdensity polyethylenes such that the polyethylene density ranges between0.90 grams per cubic centimeter to 0.97 grams per cubic centimeter,between 0.92 and 0.95 grams per cubic centimeter or any values withinthese ranges or any ranges within these values. The density of thepolyethylene may be determined by the amount and type of branching anddepends on the polymerization technology and co-monomer type.Polypropylene and/or polypropylene copolymers, including atacticpolypropylene; isotactic polypropylene, syndiotactic polypropylene, andcombination thereof can also be used. Polypropylene copolymers,especially ethylene can be used to lower the melting temperature andimprove properties. These polypropylene polymers can be produced usingmetallocene and Ziegler-Natta catalyst systems. These polypropylene andpolyethylene compositions can be combined together to optimize end-useproperties. Polybutylene is also a useful polyolefin and may be used insome embodiments. Other suitable polymers include polyamides orcopolymers thereof, such as Nylon 6, Nylon 11, Nylon 12, Nylon 46, Nylon66; polyesters or copolymers thereof, such as maleic anhydridepolypropylene copolymer, polyethylene terephthalate; olefin carboxylicacid copolymers such as ethylene/acrylic acid copolymer, ethylene/maleicacid copolymer, ethylene/methacrylic acid copolymer, ethylene/vinylacetate copolymers or combinations thereof; poly-lactic acid;polyacrylates, polymethacrylates, and their copolymers such aspoly(methyl methacrylates).

Non-limiting examples of suitable commercially available polypropyleneor polypropylene copolymers include Basell Profax PH-835 (a 35 melt flowrate Ziegler-Natta isotactic polypropylene from Lyondell-Basell), BasellMetocene MF-650W (a 500 melt flow rate metallocene isotacticpolypropylene from Lyondell-Basell), Polybond 3200 (a 250 melt flow ratemaleic anhydride polypropylene copolymer from Crompton), Exxon Achieve3854 (a 25 melt flow rate metallocene isotactic polypropylene fromExxon-Mobil Chemical), Mosten NB425 (a 25 melt flow rate Ziegler-Nattaisotactic polypropylene from Unipetrol), Danimer 27510 (apolyhydroxyalkanoate polypropylene from Danimer Scientific LLC), DowAspun 6811A (a 27 melt index polyethylene polypropylene copolymer fromDow Chemical), Eastman 9921 (a polyester terephthalic homopolymer with anominally 0.81 intrinsic viscosity from Eastman Chemical), Achieve 3155(a 35 melt flow rate zinc isotactic polypropylene from Exxon Mobil),Moplen HP561R and Moplen HP552R, both of which are 25 melt flow rateZiegler-Natta isotactic polypropylene from Lyondell-Basell).

The thermoplastic polymer component can be a single polymer species asdescribed above or a blend of two or more thermoplastic polymers asdescribed above, e.g. two different polypropylene resins. As an example,the constituent fibers of the first layer can be comprised of polymerssuch as polypropylene and blends of polypropylene and polyethylene. Thenonwoven webs/laminates may comprise fibers selected from polypropylene,polypropylene/polyethylene blends, and polyethylene/polyethyleneterephthalate blends. In some forms, the nonwoven webs/laminates maycomprise fibers selected from cellulose rayon, cotton, other hydrophilicfiber materials, or combinations thereof. The fibers can also comprise asuper absorbent material such as polyacrylate or any combination ofsuitable materials.

The fibers of the crimped fiber spunbond nonwoven webs/laminates of thepresent invention may comprise fibers which are bi-component,multi-component, and/or bi-constituent, round or non-round (e.g.,capillary channel fibers), and can have major cross-sectional dimensions(e.g., diameter for round fibers) ranging from 0.1-500 microns. Theconstituent fibers of the nonwoven precursor web may also be a mixtureof different fiber types, differing in such features as chemistry (e.g.polyethylene and polypropylene), components (mono- and bi-), denier(micro denier and >2 denier), shape (i.e. capillary and round) and thelike. The constituent fibers can range from about 0.1 denier to about100 denier.

For the nonwoven laminates of the present invention, layers of thelaminate which are not the crimped fiber spunbond nonwoven web maycomprise any of the above fibers. Additionally, such layers may comprisemonocomponent fibers as well.

Forms of the present invention are contemplated where the first layerand/or second layer comprise additives in addition to their constituentchemistry. For example, suitable additives include additives forcoloration, antistatic properties, lubrication, softness,hydrophilicity, hydrophobicity and the like and combinations thereof.These additives, for example titanium dioxide for coloration, aregenerally present in an amount less than about 5 weight percent and moretypically about 2 weight percent or less.

As used herein, the term “monocomponent” fiber refers to a fiber formedfrom one extruder using one or more polymers. This is not meant toexclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,opacity, lubrication, hydrophilicity, etc.

As used herein, the term “bi-component fibers” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bi-componentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebi-component fibers and extend continuously along the length of thebi-component fibers. The configuration of such a bi-component fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement. Some suitableexamples of bi-component fiber configurations are shown in FIG. 63. Forexample, fibers of the crimped fiber spunbond nonwoven webs of thepresent invention may comprise fibers having a cross section 6300 whichcomprises a first component 6300A and a second component 6300B arrangedin a side by side configuration. As another example, crimped fiberspunbond nonwoven webs of the present invention may comprise fibershaving a cross-section 6310 which comprises a first component 6310A anda second component 6310B in an eccentric sheath-core configuration.Another eccentric sheath-core configuration which may be utilized isshown with regard to cross-section 6320 which comprises a firstcomponent 6320A and a second component 6320B. Also, non-round fibercross-sections are contemplated. For example, the crimped fiber spunbondnonwoven webs of the present invention may comprise fibers having across-section 6330 which is tri-lobal. The tri-lobal cross section 6330comprises a first component 6330A and a second component 6330B, wherethe second component 6330B is one of the lobes of the tri-lobal crosssection.

Some specific examples of fibers which can be used in the crimped fiberspunbond nonwoven webs of the present invention includepolyethylene/polypropylene side-by-side bi-component fibers. Anotherexample, is a polypropylene/polyethylene bi-component fiber where thepolyethylene is configured as a sheath and the polypropylene isconfigured as a core within the sheath. Still another example, is apolypropylene/polypropylene bi-component fiber where two differentpropylene polymers are configured in a side-by-side configuration. Stillanother example, is polypropylene/poly-lactic acid bi-component fiber.Still another example is polyethylene/poly-lactic acid bi-componentfiber. For the bi-component fibers of polyethylene/poly-lactic acid,such fibers may be produced from renewable resources. For example, boththe polyethylene and polylactic acid may be bio sourced. Additionally,polypropylene and poly-lactic acid based fibers would typically notwithstand the out-of-plane deformation processing described herein;however, when configured as a crimped fiber, such fibers may withstandsaid processing.

Bi-component fibers may comprise two different resins, e.g. a firstresin and a second resin. The resins may have different melt flow rates,molecular weights, branching, viscosity, crystallinity, rate ofcrystallization, and/or molecular weight distributions. Ratios of the 2different polymers may be about 50/50, 60/40, 70/30, 80/20, 90/10 or anyratio within these ratios. The ratio may be selected to control theamount of crimp, strength of the nonwoven layer, softness, bonding orthe like.

As used herein, the term “bi-constituent fibers” refers to fibers whichhave been formed from at least two polymers extruded from the sameextruder as a blend. Bi-constituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross-sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Bi-constituent fibers are sometimes also referred to asmulti-constituent fibers. In other examples, a bi-component fiber maycomprise a multiconstituent components.

As used herein, the term “non-round fibers” describes fibers having anon-round cross-section, and includes “shaped fibers” and “capillarychannel fibers.” Such fibers can be solid or hollow, and they can betri-lobal, delta-shaped, and can be fibers having capillary channels ontheir outer surfaces. The capillary channels can be of variouscross-sectional shapes such as “U-shaped”, “H-shaped”, “C-shaped” and“V-shaped”. One practical capillary channel fiber is T-401, designatedas 4DG fiber available from Fiber Innovation Technologies, Johnson City,Tenn. T-401 fiber is a polyethylene terephthalate (PET polyester).

The basis weight of nonwoven materials is usually expressed in grams persquare meter (gsm). The basis weight of a single layer nonwoven materialcan range from about 8 gsm to about 100 gsm, depending on the ultimateuse of the material. For example, each layer of a nonwoven laminate ofthe present invention may have a basis weight from about 8 to about 40gsm or from about 8 to about 30 gsm. The basis weight of a multi-layermaterial is the combined basis weight of the constituent layers and anyother added components. The basis weight of multi-layer materials ofinterest herein can range from about 20 gsm to about 150 gsm, dependingon the ultimate use of the material.

As noted previously, at least one of the webs of the laminates of thepresent invention comprises spunbond crimped fibers. The other web(s)may be selected from any suitable type of material. Some suitableexamples include spunbond nonwoven webs, thermally point bondedspunbond, carded nonwoven webs, through air bonded or hydroentanglednonwoven webs. Any suitable film may also be utilized.

Regarding the crimped fiber spunbond nonwoven webs/laminates of thepresent invention, the precursor materials may have certain desiredcharacteristics. For example, the precursor materials each have a firstsurface, a second surface, and a thickness. The first and secondsurfaces of the precursor materials may be generally planar. And forthose layers of the laminates of the present invention which are notcrimped fiber spunbond nonwoven webs, it may be desirable for theprecursor materials to have extensibility to enable the fibers tostretch and/or rearrange into the form of the apertures, tufts and/orcaps. Extensibility is desirable in order to maintain at least somenon-broken fibers in the sidewalls around the perimeter of the tuftsand/or caps and to aperture without causing significant fiber breakingor web tearing. It may be desirable for individual precursor materials,or at least one of the webs within the laminates, to be capable ofundergoing an elongation of greater than or equal to about one of thefollowing amounts: 100% (that is double its unstretched length), 110%,120%, or 130% up to about 200%, up to about 250% or more, at or beforereaching the peak tensile force. It may also desirable for the precursormaterials to be capable of undergoing plastic deformation to ensure thatthe structure of the out-of-plane deformations is “set” in place so thatthe nonwoven laminate will not tend to recover or return to its priorconfiguration. However, in the case crimped fiber spunbond webs, it maybe desirable for the precursor material for these specific web(s) to becapable of experiencing no or minimal plastic deformation duringprocessing.

As stated previously, in contrast to spunbond nonwoven webs, theconstituent fibers of the crimped fiber spunbond nonwoven webs typicallyare uncoiled and/or displaced when processed as described herein.Because the crimped fibers tend to coil to some extent, the out-of-planeprocessing described herein typically displaces/uncoils the crimpedfibers as opposed to plastically deforming the crimped fibers. As such,the crimped fibers have a different stress-strain profile versusconventional spunbond fibers.

Extensibility of a nonwoven web can be impacted by calendar bondingbetween constituent fibers. This is true for both spunbond nonwovenlayers and crimped fiber spunbond nonwoven layers. For example, toincrease extensibility in a nonwoven web, it may be desirable for thenonwoven web to be underbonded as opposed to optimally bonded prior toprocessing. A thermally bonded nonwoven web's tensile properties can bemodified by changing the bonding temperature. A web can be optimally orideally bonded, underbonded or overbonded. Optimally or ideally bondedwebs are characterized by the highest peak tensile strength andelongation at tensile peak with a rapid decay in strength after tensilepeak. Under strain, bond sites fail and a small amount of fibers pullout of the bond site. Thus, in an optimally bonded nonwoven, the fiberswill stretch and break around the bond sites when the nonwoven web isstrained beyond a certain point. Often there is a small reduction infiber diameter in the area surrounding the thermal point bond sites.Underbonded webs have a lower peak tensile strength and elongation attensile peak when compared to optimally bonded webs, with a slow decayin strength after tensile peak. Under strain, some fibers will pull outfrom the thermal point bond sites. Thus, in an underbonded nonwoven, atleast some of the fibers can be separated easily from the bond sites toallow the fibers to pull out of the bond sites and rearrange when thematerial is strained. Overbonded webs also have a lowered peak tensilestrength and elongation at tensile peak when compared to optimallybonded webs, with a rapid decay in strength after tensile peak. Theabove calendar bond sites look like films and result in complete bondsite failure under strain.

Similarly, extensibility of crimped fiber spunbond nonwoven webs can beimpacted by the degree of crimp in the constituent fibers. The more curlthat the fibers comprise, the higher the tensile elongation of thecrimped fiber spunbond nonwoven web. The level of curl of a crimpedfiber spunbond nonwoven web can be tailored based upon materialselection, ratio of the two polymers of the bi-component fiber, fibercross section, amount of draw in the spunbond process, heat treatments,and melt additives. Additionally, the inventors have found that with anarrower molecular weight distribution in the material selection, morecrimp can be achieved.

In some forms nonwoven laminates of the present invention may beconfigured with constituent nonwoven webs which have differing levels ofextensibility. For example, a lower web may comprise a nonwoven havinggreater extensibility than an upper layer. In such configurations, afterprocessing to create tufts/caps, there is a greater likelihood ofcreating tufts with no corresponding caps.

For crimped fiber spunbond nonwoven webs, calendar bonding of the web isalso important. As shown in FIGS. 12A-15B, too low of a calendar bondarea does not allow for good formation of tufts/caps. And too low of acalendar bond area yields a web with low strength and poor abrasionresistance. However, too high of a calendar bond area reduces the lengthof fibers between bonds which inhibits the amount of uncoiling and/ordisplacement possible. Specifically, too high of a calendar bond areainhibits the movement of the fibers such that when subjected to theprocessing described herein for the formation of tufts/caps, the crimpedfibers have very limited ability to uncoil. In such configurations, thecrimped fibers must undergo plastic deformation or break once the amountof uncoiling surpasses the amount of applied process strain. Theinventors have found that calendar bond area above about 10 percent andless than about 18 percent allows for a good balance of fiber mobilityand free fiber length available for uncoiling but still providessufficient strength in the crimped fiber spunbond nonwoven web formanipulations of the crimped fiber spunbond nonwoven web as well asabrasion and tearing resistance in use.

FIGS. 12A and 12B depict nonwoven laminates of the present inventioncomprising a crimped fiber spunbond nonwoven webs as the upper and lowerlayers. With regard to FIGS. 12A and 12B, the upper layer has a calendarbond area of about 10 percent while the lower layer has a bond area ofabout 12 percent. As shown, the tufts/caps 1230 are not very welldefined. It is believed that with a bond area of below about 10 percentthat there is too much fiber mobility and the fibers are not able toretain a tuft/cap form.

With regard to FIGS. 13A and 13B, both the upper and lower layers have acalendar bond area of about 12 percent. In contrast with the tufts/capsof FIGS. 12A and 12B, the tufts/caps 1330 of FIGS. 13A and 13B are moreclearly defined. Namely, the tufts/caps 1330 have some recognizableshape in comparison to the surrounding crimped fibers.

With regard to FIGS. 14A and 14B, both the upper and lower layers have acalendar bond area of about 14.6 percent. Much like the tufts/caps 1330of FIGS. 13A and 13B, the tufts/caps 1430 are more clearly defined overthe tufts/caps 1230 of FIGS. 12A and 12B.

With regard to FIGS. 15A and 15B, both the upper and lower layers have acalendar bond area of about 18 percent. While the tufts/caps 1530 arewell defined, the tufts/caps 1530 are not as fluffy as those depictedwith the about 12 percent or about 14.6 percent bond area. As statedpreviously, it is believed that higher calendar bond areas inhibit thefiber movement and create lower path length for uncoiling of the crimpedfibers. Namely, with a higher calendar bond area percentage, the crimpedfibers have a shorter path length to uncoil and so will be forced tothin or break at a lower process strain. It is further believed thatwith calendar bond areas greater than about 18 percent, the softness,loft and permeability would also be negatively impacted as well as lowerresultant strength due to increased fiber breakage.

In some forms of the present invention, the crimped fiber spunbondnonwoven webs may comprise a calendar bond area of between about 10percent to about 18 percent or between about 12 percent and 16 percentor any value within these ranges. Spunbond nonwoven layers (not crimped)may comprise a calendar bond area of between about 5 percent to about 30percent, between about 10 percent to about 20 percent, or any valuewithin these ranges. The nonwoven webs may be bonded or underbonded asdescribed above. The bonds can be shaped like dots, diamonds, ovals orany other suitable shape and may be arranged in any suitable pattern toprovide the desired mechanical properties.

The webs of a nonwoven laminate of the present invention can be combinedtogether in any suitable manner. In some cases, the layers can beunbonded to each other and held together autogenously (that is, byvirtue of the formation of out-of-plane deformations therein). Forexample, both layers of the precursor materials may contribute fibers toout-of-plane deformations in a “nested” relationship that “locks” theprecursor materials together, forming a multi-layer laminate without theuse or need for adhesives or thermal bonding between the webs. In otherforms, the webs can be joined together by other mechanisms. If desiredan adhesive between the webs, ultrasonic bonding, chemical bonding,resin or powder bonding, thermal bonding, or bonding at discrete sitesusing a combination of heat and pressure can be selectively utilized tobond certain regions or all of the precursor webs. If adhesives areused, they can be applied in any suitable manner or pattern including,but not limited to: slots, spirals, spray, and curtain coating.Adhesives can be applied in any suitable amount or basis weightincluding, but not limited to between about 0.5 and about 30 gsm,alternatively between about 2 and about 5 gsm. Still in otherconfigurations, the nonwoven layers may be combined together via anaperturing process. For example, two nonwoven webs may be fused togetherat a plurality of discrete locations—overbonds. The discrete locationsmay be subjected to incremental stretching which causes the discretelocations to fracture thereby forming an aperture. In general, at theperimeter of the aperture, the nonwoven webs are joined together via amelt/fused lip. The melt/fused lip can define at least a portion of anaperture perimeter when created via overbonding.

In other forms, the constituent nonwoven webs may comprise minimalfiber-to-fiber bonds. For example, the first layer and/or second layercan have a pattern of discrete thermal point bonds, as is commonly knownin the art for nonwoven webs. However, as discussed previously, bondedarea can impact the resultant structures of the nonwoven layers. Ingeneral, using fibers having relatively high diameters, and/orrelatively high extension to break, and/or relatively high fibermobility, might result in better and more distinctly formed tufts and/orcaps. In another embodiment, the nonwoven webs can be through air bondednonwoven material.

The constituent nonwoven webs of the nonwoven laminates of the presentinvention may be provided with structural integrity via a variety ofdifferent processes. Some examples include thermal point bonding, airthrough bonding, hydroentangling, and needlepunching each of which iswell known in the art.

In some forms, the constituent fibers of the first nonwoven web areselected such that the first nonwoven web is hydrophobic, and theconstituent fibers of the second nonwoven web are selected such that thesecond nonwoven web is hydrophilic.

As noted previously, some laminates of the present invention mayadditionally comprise film. Any suitable film may be utilized. Somesuitable examples include those described in U.S. Pat. Nos. 3,929,135;4,324,426; 4,324,314; 4,629,643; 4,463,045; and 5,006,394. Wherelaminates comprising film are utilized, the film may be extrudeddirectly onto the crimped fiber spunbond nonwoven web during the makingof the laminate.

Nonwoven Web/Laminate Processing

The manufacture of the crimped fiber spunbond nonwoven webs/laminates ofthe present invention may be via any suitable method. The first layerand/or second layer can be produced via the spunbonding nonwoven processwhich is well known in the art.

Depending on the orientations of caps and tufts described heretofore,processing of crimped fiber spunbond nonwoven laminates of the presentinvention can vary. Referring to FIG. 16A, there is shown an apparatus800 and method for producing the crimped fiber spunbond nonwovenwebs/laminates of the present invention. The apparatus 800 comprises apair of intermeshing rolls 802 and 804, each rotating about an axisA—the axes A being parallel and in the same plane. Roll 802 comprises aplurality of ridges 806 and corresponding grooves 808 which can extendunbroken about the entire circumference of roll 802.

Roll 804 is similar to roll 802, but rather than having ridges thatextend unbroken about the entire circumference, roll 804 comprises aplurality of rows of circumferentially-extending ridges that have beenmodified to be rows of circumferentially-spaced teeth 811 that extend inspaced relationship about at least a portion of roll 804. The individualrows of teeth 811 of roll 804 are separated by corresponding grooves812. In operation, rolls 802 and 804 intermesh such that the ridges 806of roll 802 extend into the grooves 812 of roll 804 and the teeth 811 ofroll 804 extend into the grooves 808 of roll 802. A nip 816 is formedbetween the counter-rotating intermeshing rolls 802 and 804. Both oreither of rolls 802 and 804 can be heated by means known in the art suchas by using hot oil filled rollers or electrically-heated rollers.

The apparatus 800 is shown in a configuration having one patterned roll,e.g., roll 804, and one non-patterned grooved roll 802. However, incertain embodiments it may be preferable to use two patterned rollssimilar to roll 804 having either the same or differing patterns, in thesame or different corresponding regions of the respective rolls. Such anapparatus can produce laminates with tufts protruding from both sides ofthe nonwoven laminate of the present invention.

Nonwoven laminates of the present invention can be made by mechanicallydeforming the first layer and the second layer that can each bedescribed as generally planar and two dimensional prior to processing bythe apparatus shown in FIG. 16A. By “planar” and “two dimensional” ismeant simply that the laminates start the process in a generally flatcondition relative to the finished nonwoven laminate that has distinct,out-of-plane, Z-direction three-dimensionality due to the formation oftufts and/or caps. “Planar” and “two-dimensional” are not meant to implyany particular flatness, smoothness or dimensionality.

Some nonwoven laminates of the present invention described herein can beprocessed as described above with some variation. For example, in orderto accomplish the negative Z-direction urging as described herein, thenonwoven webs may be provided to the apparatus 800 such that the secondlayer is disposed superjacent to the first layer. However, flipping theresultant nonwoven laminate at rapid production speeds for processingcould prove difficult to manage and may introduce much complexity intothe production of such nonwoven laminates. Alternatively, for thecreation of tufts and/or caps protruding in the negative Z-direction,the rolls 802 and 804 of apparatus 800 can be inverted. For example, thepatterned roll 804 may be positioned superjacent to the non-patternedgrooved roll 802.

The number, spacing, and dimensions of tufts and/or caps can be variedto give varying texture to crimped fiber spunbond nonwovenwebs/laminates of the present invention. For example, if tufts and/orcaps are sufficiently closely spaced the resultant nonwoven laminate canhave a terry cloth-like feel. Alternatively, tufts and/or caps can bearranged in patterns such as lines or filled shapes to create portionsof a laminate having greater texture, softness, bulk, absorbency orvisual design appeal. For example, when tufts and/or caps are arrangedin a pattern of a line or lines, the tufts and/or caps can have theappearance of stitching. Likewise, the size dimensions, such as theheight, length and width of individual tufts can be varied.

Single tufts and/or caps can be as long as about 3 cm in length and canbe made alone or dispersed among tufts and/or caps of various sizes. Insome embodiments, the tufts and/or caps may have a length ranging fromabout 1 mm to about 10 mm. In some embodiments, the tufts and/or capsmay have a length ranging from about 2 mm to about 8 mm; from about 3 mmto about 7 mm, or any ranges within the values recited or any numberswithin the values recited.

Additionally, forms of crimped fiber spunbond nonwoven webs/laminatesare contemplated which comprise a plurality of tufts and/or caps whichare configured differently. For example, a nonwoven laminate of thepresent invention may comprise a tuft 270 (shown in FIGS. 2A-2C) and acap 230 (shown in FIGS. 2A-2C) in a first area of the nonwoven laminateand may comprise a tuft 370 (shown in FIG. 3) in a second area of thenonwoven laminate without a corresponding cap. In another example,nonwoven laminate of the present invention may comprise a tuft 470(shown in FIG. 4) in a first area of a nonwoven laminate and maycomprise a tuft 270 and a cap 230 (shown in FIGS. 2A-2C) in a secondarea of the nonwoven laminate. In yet another example, a nonwovenlaminate of the present invention may comprise a tuft 370 (shown in FIG.3) in a first area of the nonwoven laminate and a tuft 470 (shown inFIG. 4) in a second area of the nonwoven laminate. In yet anotherexample, a nonwoven laminate of the present invention may comprise atuft 270 and a cap 230 (shown in FIGS. 2A-2C) in a first area of thenonwoven laminate and a tuft 570 and a cap 530 (shown in FIG. 5) in asecond area of the nonwoven laminate. In yet another example, a nonwovenlaminate of the present invention may comprise a tuft 570 and a cap 530(shown in FIG. 5) in a first area of the nonwoven laminate and a tuft370 (shown in FIG. 3) in a second area of the nonwoven laminate. In yetanother example, a nonwoven laminate of the present invention maycomprise a tuft 570 and a cap 530 (shown in FIG. 5) in a first area ofthe nonwoven laminate and may comprise a tuft 470 (shown in FIG. 4) in asecond area of the nonwoven laminate. Crimped fiber spunbond nonwovenwebs/laminates of the present invention may utilize any and allcombinations of the tufts and/or caps described with regard to FIGS.2A-2C and 3-5), e.g. first area with first set of tufts and/or caps,second area with second set of tufts and/or caps, third area with thirdset of tufts and/or caps, and so on, wherein each of the first, secondand third sets of tufts and/or caps are different. Additional examplesinclude variation in spacing between tufts/caps in addition to orindependent of variations in the tufts/caps themselves.

Referring back to FIG. 16A, the first layer and the second layer can bemoved in the machine direction to the nip 816 of counter-rotatingintermeshing rolls 802 and 804. The first layer and the second layer arepreferably held in a sufficient web tension so as to enter the nip 816in a generally flattened condition by means well known in the art of webhandling. As each of the first layer and the second layer goes throughthe nip 816, the teeth 810 of roll 804—which are intermeshed withgrooves 808 of roll 802—simultaneously urge fibers of the first layerout of the plane of the first layer thereby forming caps and urge fibersof the second layer out of the plane of the second layer and through theplane of the first layer to form tufts.

The number, spacing, and size of tufts and/or caps can be varied bychanging the number, spacing, and size of teeth 811 and makingcorresponding dimensional changes as necessary to roll 804 and/or roll802. This variation, together with the variation possible in first layerand the second layer permits many varied crimped fiber spunbond nonwovenlaminates to be made for many purposes. The size of teeth as well asadditional details regarding processing of nonwovens and laminatescomprising nonwovens can be found in U.S. Pat. Nos. 7,410,683;7,789,994; 7,838,099; 8,440,286; and 8,697,218.

The out-of-plane deformations disclosed herein with regard to FIGS.2A-9B, may be provided in arrays or a plurality thereof. Such arrays ofout-of-plane deformations or plurality of arrays of structures maycomprise a pattern or a plurality of patterns which form graphics and/orother depictions, hereafter, “structural indicia.” Additional forms arecontemplated where the out-of-plane deformations described herein may beutilized in any combination.

As stated previously, the first layer and the second layer, as describedherein, may be provided as discrete layers. For example, forms arecontemplated where the first layer is derived from a first supply rollhaving a first specific fiber makeup while the second layer is derivedfrom a second supply roll having a second specific fiber makeup. In someembodiments, the fiber makeup between the first supply roll and thesecond supply roll can be different as described herein.

The crimped fiber spunbond nonwoven webs of the present invention may beprocessed similar to the laminates described herein. For those formsincluding a crimped fiber spunbond nonwoven web and a film layer,processing may be as described above. However, the film layer may besubjected to additional processing in an effort to enhance thesoftness/feel of the film. Such processing of film layers is disclosedin U.S. Patent Application Publication No. 2005/0214506; U.S. Pat. Nos.4,609,518; 4,629,643; 4,637,819; 4,681,793; 4,695,422; 4,778,644;4,839,216; and 4,846,821.

Additional forms are contemplated where crimped fiber spunbond nonwovenwebs are utilized which comprise a heterogeneous structure. For example,as shown in FIG. 16B, a crimped fiber spunbond nonwoven web of thepresent invention may be produced via a spunbond process comprisingmultiple spinbeams 855, 857. In some forms, the first spinbeam 855 maydeposit a first plurality of continuous fibers 861 onto a belt. Thefirst plurality of continuous fibers 861 may comprise crimped fibers,e.g. side by side configurations. The second spinbeam 857 may deposit asecond plurality of continuous fibers 863 onto the belts over the top ofthe first plurality of continuous fibers 861. The second plurality ofcontinuous fibers may be configured differently than the first pluralityof continuous fibers. For example, in some forms, the second pluralityof continuous fibers may comprise non crimped fibers—straight fibers. Anexample of crimped fiber versus straight fiber is shown in FIGS. 16C and16D, respectively. Additional forms are contemplated where the firstplurality of continuous fibers 861 comprises a first melt additive, andthe second plurality of continuous fibers 863 comprises a second meltadditive. In some forms of the present invention, the melt additives canbe different. For example, the first melt additive may be hydrophilicwhere the second melt additive is hydrophobic. In other forms, the firstplurality of continuous fibers 861 may be chosen such that the fibersare hydrophilic and the second plurality of continuous fibers 863comprises crimped fibers which comprise a hydrophobic melt additive.

In some forms, the first plurality of continuous fibers 861 and thesecond plurality of continuous fibers 863 may be the same such that theresultant crimped fiber spunbond nonwoven web is homogeneous with regardto the fibers. Additional beams may be provided to provide additionalcontinuous fibers or melt-blown fibers. In some forms, a single beam maybe utilized to produce a crimped fiber spunbond nonwoven web.

Additives

And as noted previously, the first layer may include a hydrophobic meltadditive and/or the second layer may include a hydrophilic melt additiveor topical hydrophilic. Still in other forms, the nonwoven laminates ofthe present invention may be configured such that the first web is morehydrophobic than the second web either via additive, fiber materialselection, or combinations thereof. In other forms, the hydrophobicadditive and/or hydrophilic additive may be sprayed on or otherwisetopically applied. Additional additives are contemplated. For example,an additive for softness may be added to any of the crimped fiberspunbond nonwoven webs or crimped fiber spunbond nonwoven laminates. Asuitable example of an additive for softness includes Erucamide whichmay be provided in amounts ranging from about 1 to about 20 percent byweight.

Hydrophobic Additive

In addition to selecting constituent precursor materials which exhibitthe desired hydrophobic/hydrophilic qualities, other methods arecontemplated for producing the hydrophobic/hydrophilic gradient asdescribed above. For example, crimped fiber nonwoven webs and/or othernonwoven webs in the case of a laminate described herein may comprise anadditive which blooms on a surface of at least a portion of a firstplurality of fibers. In some forms, the additive may be added directlyto the fibers or as master batch to the polymer melt during spinning ofthe filaments as a melt additive. Where the additive is melt blendedinto the filaments, the additive can bloom to the surface of the fibersand create a film covering a portion of the external surface of thefiber and/or can create fibrils, flakes, particles, and/or other surfacefeatures. For those fibers comprising fibrils, the fibrils may extendoutwardly, or radially outwardly, from the surface.

While the fibrils extend outwardly from surfaces of individual fibers,the fibrils may also extend to or from (i.e., contact) other fiberswithin the same layer or a different layer of a nonwoven web and/or tofibrils extending from fibers within the same layer or a different layerof the nonwoven laminate. When the fibrils extend between fibers and/orother fibrils, the nonwoven web may achieve a greater liquid contactangle for polar and non-polar liquids. A similar effect may be obtainedfor additives which are applied to the first plurality of fibers postproduction. Without wishing to be bound by theory, it is believed thatthe additive, regardless of whether a melt additive or applied postfiber production, changes the surface energy of the constituent fibers.The change in surface energy increases the hydrophobic nature of theconstituent fibers and therefore the nonwoven web. Additionally, it isbelieved that the additive, whether a melt additive or applied postfiber production, increases the surface roughness of the constituentfibers which can increase hydrophobicity. It is believed that anincrease in hydrophobicity due to surface roughness is achieved bymetastable Wenzel and stable Cassie-Baxter non-wetting states.

The additive suitable for the present invention may be any suitablehydrophobic additive. Thus, the additives may increase thehydrophobicity of the fibers upon whose surface they bloom. This canlead to increased low surface tension fluid strikethrough times andhigher hydrophobicity for the nonwoven web.

Some examples of suitable additives include fatty alcohols and fattyacid esters. Non-limiting examples of suitable fatty alcohols havingfrom about 12 to about 24 carbon atoms include saturated,un-substituted, monohydric alcohols or combinations thereof, which havea melting point less than about 110° C., preferably from about 45° C. toabout 110° C. Specific examples of fatty alcohol carriers for use in theskin care compositions of the present invention include, but are notlimited to, cetyl alcohol, stearyl alcohol, cetearyl alcohol, behenylalcohol, arachidyl alcohol, lignocaryl alcohol, and combinationsthereof. Examples of commercially available cetearyl alcohol are Stenol1822 and behenyl alcohol is Lanette 22, both of which are available fromthe Cognis Corporation located in Cincinnati, Ohio.

Non-limiting examples of suitable fatty acid esters include those fattyacid esters derived from a mixture of C₁₂-C₂₈ fatty acids and shortchain (C₁-C₈, preferably C₁-C₃) monohydric alcohols preferably from amixture of C₁₆-C₂₄ saturated fatty acids and short chain (C₁-C₈,preferably C₁-C₃) monohydric alcohols. Representative examples of suchesters include methyl palmitate, methyl stearate, isopropyl laurate,isopropyl myristate, isopropyl palmitate, ethylhexyl palmitate, andmixtures thereof. Suitable fatty acid esters can also be derived fromesters of longer chain fatty alcohols (C₁₂-C₂₈, preferably C₁₂-C₁₆) andshorter chain fatty acids such as lactic acid, specific examples ofwhich include lauryl lactate and cetyl lactate.

The additives of the present disclosure, may have a melting point in therange of about 40 degrees C. to about 80 degrees C., about 55 degrees C.to about 75 degrees C., about 60 degrees C. to about 73 degrees C.,specifically reciting all one degree C. increments within the specifiedranges and all ranges formed therein or thereby. The additives of thepresent disclosure may have a melting temperature above 30° C., above40° C., or above 50° C., but less than 80 degrees C., including allranges within the values expressed and all numbers within the rangescreated by the values expressed.

The additive may have a hydrophilic/lipophilic balance (“HLB”) value ofless than about 4. In some forms, the HLB value may be greater thanabout 0 and less than about 4, between about 1 and about 3.5, betweenabout 2 and about 3.3, or any ranges within the values provided or anyvalue within the ranges provided. It is believed that above an HLB valueof about 4, the additive will start to take on more surfactant-likehydrophilic properties and would thereby reduce the benefit provided bythe highly hydrophobic additive. Namely, as mentioned previously, thehydrophobic additive can provide a masking benefit which makes thedisposable absorbent article utilizing the nonwoven webs/laminates ofthe present invention appear more “clean” after a liquid insult hasoccurred.

In some forms, the additive may have an IOB (inorganic value/organicvalue) value of greater than about 0 and less than about 0.4, betweenabout 0.1 and about 0.35, between about 0.2 and 0.33, specificallyincluding all values within these ranges and any ranges created thereby.The IOB value is discussed in additional detail in EP Patent ApplicationPublication No. 2517689.

The additives used, may comprise fatty acid derivatives, such as a fattyacid ester; typically an ester formed from an alcohol with two or morehydroxyl groups and one or more fatty acids having between at least 12carbon atoms to 22 carbon atoms, or at least 14 carbon atoms, wherebywithin one ester compound, different fatty acid-derived groups may bepresent (herein referred to as fatty acid ester).

The fatty acid ester compound may be an ester of an alcohol carrying twoor more, or three or more, functional hydroxyl group per alcoholmolecule, whereby all of the hydroxyl groups form an ester bond withfatty acids (either the fatty acid or mixtures thereof).

In some forms, the alcohol may have three functional hydroxyl groups. Itis understood that in a fatty acid ester having more than one esterbond, such as in di- or tri-glycerides, the fatty acid-derived group maybe the same, or they may be two or even three different fattyacids-derived groups. It is further understood that the additivecomponent may comprise a mixture of mono- di- and/or tri-fatty acidester (e.g. mono- di-, and/or triglyceride) esters with the samefatty-acid derived group per molecule, and/or with different fattyacid-derived groups without exceeding the scope of the invention.Preferred fatty acids in at least one embodiment may range from a C8fatty acid to a C30 fatty acid; or, in another embodiment range from aC12 fatty acid to a C22 fatty acid. Suitable vegetable fatty acidstypically include unsaturated fatty acids. The fatty acid may suitablybe selected from the group comprising an arachidec acid, a stearic acid,a palmitic acid, a myristic acid, a myristoleic acid, an oleic acid, alimoleic acid, a linolenic acid, and an arachidonic acid. In anotherfurther embodiment, a substantially saturated fatty acid is preferred,particularly when saturation arises as a result of hydrogenation offatty acid precursor. The fatty acids may range from a C12 fatty acid toa C22 fatty acid as illustrated in [1],

where R1′ R2, and R3 each have a number of carbon atoms ranging from 11to 21. In at least one other embodiment, the fatty acids may range froma C16 fatty acid to a C20 fatty acid.

In some forms, a substantially saturated fatty acid is preferred,particularly when saturation arises as a result of hydrogenation offatty acid precursor. In at least one further form, a C18 fatty acid,stearic acid, is preferred. An example of the stearic acid-substitutedfatty acid is[2-octadecanoyloxy-1-(octadecanoyloxymethyl)ethyl]octadecanoate having aCAS registry number of 555-43-1. It should be understood that thepreferred triglyceride ester has an esterified glycerol backbone havingno non-hydrogen sub-stituents on the glycerol backbone.

In some forms, the one or more additives may comprise a mono- and/ordi-glyceride ester, and/or a triglyceride ester, (with one, two or threefatty acid-derived groups). It should be understood that while [1]illustrates a simple triglyceride in which all three pendent fatty acidsmay be the same, other embodiments may include a mixed triglyceride inwhich two or even three different pendent fatty acids are presentwithout exceeding the scope of the invention. It should be furtherunderstood that while the triglyceride ester is illustrated in [1] is asingle triglyceride ester formulation, the triglyceride ester used inthe preparation of the master batch may include a plurality oftriglyceride esters having different pendent fatty acid groups and/orone or more derivatives of the fatty acid, without exceeding the scopeof the invention. It should be further understood that while thetriglyceride ester illustrated in [1] is a monomer, the triglycerideester used in the preparation of the master batch may include apolymerized triglyceride ester, such as a polymerized, saturatedglyceride ester without exceeding the scope of the invention. It shouldbe further understood that the polymerized triglyceride ester maycomprise a mixture of polymers having different numbers of monomericunits included in the polymer. For example the polymerized triglycerideester may include a mixture of monoesters, diesters, and the like.

The fatty acids used to form the ester compounds include fatty acidderivatives for the purpose of the present disclosure. A mono-fatty acidester, or for example, a mono-glyceride, comprises a single fatty acid,e.g., connected a glycerol; a di-fatty acid ester, or e.g.,di-glyceride, comprises two fatty acids, e.g., connected to theglycerol; a tri-fatty acid ester, or e.g. tri-glyceride, comprises threefatty acids, e.g., connected to a glycerol. In an embodiment, theadditive may comprise at least a triglyceride ester of fatty acids(i.e., the same or different fatty acids).

It should be understood that the triglyceride ester may have anesterified glycerol backbone having no nonhydrogen substituents on theglycerol backbone; however, the glycerol backbone may also compriseother substituents. In some forms, the glycerol backbone of the glycerolester may only comprise hydrogen. The glyceride esters may also comprisepolymerized (e.g., tri) glyceride esters, such as a polymerized,saturated glyceride esters.

In a fatty acid ester having more than one ester bond, such as in di- ortri-glycerides, the fatty acid-derived group may be the same, or theymay be two or even three different fatty acids-derived groups.

The additive may comprise a mixture of mono-, di-, and/or tri-fatty acidester (e.g., mono- di- and/or triglyceride) esters with the samefatty-acid derived group per molecule, and/or with different fattyacid-derived groups.

The fatty acids may originate from vegetable, animal, and/or syntheticsources. Some fatty acids may range from a C8 fatty acid to a C30 fattyacid, or from a C12 fatty acid to a C22 fatty acid. Suitable vegetablefatty acids typically include unsaturated fatty acids such as oleicacid, palmitic acid, linoleic acid, and linolenic acid. The fatty acidmay be arachidec, stearic, palmitic, myristic, myristoleic, oleic,limoleic, linolenic, and/or arachidonic acid.

In some forms, a substantially saturated fatty acid may be used,particularly when saturation arises as a result of hydrogenation offatty acid precursor. In an embodiment, a C18 fatty acid, oroctadecanoic acid, or more commonly called stearic acid may be used toform an ester bond of the fatty acid ester herein; stearic acid may bederived from animal fat and oils as well as some vegetable oils. Thestearic acid may also be prepared by hydrogenation of vegetable oils,such as cottonseed oil. The fatty acid ester herein may comprise fattyacids of mixed hydrogenated vegetable oil, such as one having CASregistration number 68334-28-1.

At least one stearic acid, at least two, or three stearic acids areconnected to a glycerol, to form a glycerol tristearate, for theadditive herein. In an embodiment, the additive may comprise a glyceroltristearate (CAS No. 555-43-1), also known by such names as tristearinor 1,2,3-Trioctadecanoylglycerol. (In the following, the name glyceroltristearate will be used, and in case of doubt the CAS No., shall beseen as the primary identifier).

In some forms, additives with chemical structures similar to glyceroltristearate or tristearin such as triacylglycerols (triglycerides)including but not limited to trimyristin, tripalmitin, trilaurin,trimargarine, and waxes such as distearin, and mixtures of saturated andunsaturated glycerides, such as 1,3-distearoyl-2-oleoylglycerol (SOS)may be utilized. Non-limiting examples additives having molecular andcrystallite structures as similar to tristearin include Alkylketenedimers (AKD), inorganic and organic salts of fatty acids (also known asalkyl carboxylic acids) that comprise of alkyl chains that are mostlysaturated, and contain between 12 and 22 carbon atoms. Non-limitingexamples of salts of fatty acids include zinc stearate, calciumstearate, magnesium stearate, titanium stearate, silver stearate,aluminum di- and tri-stearates, aluminum tripalmitate, aluminumtrimyristate, aluminum trilaurate, sorbitan tristearate, sorbitantripalmitate, sorbitan trimyristate, sorbitan trilaurate, andcombinations thereof, which are believed to form flaky and fibrillarlamellar structures on surfaces due to blooming.

In some forms, the fatty acid ester of the additive may have anumber-averaged molecular weight ranging from 500 to 2000, from 650 to1200, or from 750 to 1000, specifically reciting all whole integerincrements within the above-specified ranges and any ranges formedtherein or thereby.

The additive may comprise very little or no halogen atoms; for example,the additive may comprise less than 5 wt. % halogen atoms (by weight ofthe additive), or less than 1 wt. %, or less than 0.1 wt. % of theadditive; the additive may be substantially halogen-free.

In some forms, the additive may be or may comprise a lipid ester orglycerol tristearate. In various forms, the fibrils may comprise,consist of, or consist essentially of (i.e., 51% to 100%, 51% to 99%,60% to 99%, 70% to 95%, 75% to 95%, 80% to 95%, specifically includingall 0.1% increments within the specified ranges and all ranges formedtherein or thereby) of the additive.

Nonlimiting examples of suitable alkyl ethoxylates include C₁₂-C₂₂ fattyalcohol ethoxylates having an average degree of ethoxylation of fromabout 2 to about 30. Non-limiting examples of suitable lower alcoholshaving from about 1 to about 6 carbon atoms include ethanol,isopropanol, butanediol, 1,2,4-butanetriol, 1,2 hexanediol, etherpropanol, and mixtures thereof. Non-limiting examples of suitable lowmolecular weight glycols and polyols include ethylene glycol,polyethylene glycol (e.g., Molecular Weight 200-600 g/mole), butyleneglycol, propylene glycol, polypropylene glycol (e.g., Molecular Weight425-2025 g/mole), and mixtures thereof.

The master batch added to the composition from which the fibers of thepresent disclosure are formed may be the master batch disclosed in U.S.Pat. No. 8,026,188 to Mor.

In some forms, the fibrils may grow out of the fibers post-nonwovensubstrate formation under ambient conditions. The fibrils may benoticeable using an SEM after about 6 hours post-nonwoven substrateformation under ambient conditions. Fibril growth may reach a plateauafter about 50 hours, 75 hours, 100 hours, 200 hours, or 300 hourspost-nonwoven substrate formation under ambient conditions. In someembodiments, fibril growth may continue well beyond 300 hours. The timerange of noticeable fibril growth post-nonwoven substrate formation maybe in the range of 1 minute to 300 hours, 5 hours to 250 hours, 6 hoursto 200 hours, 6 hours to 100 hours, 6 hours to 24 hours, 6 hours to 48hours, or 6 hours to 72 hours, under ambient conditions, specificallyreciting all 1 minute increments within the above specified ranges andall ranges formed therein or thereby. The time to allow full fibrilgrowth post-nonwoven substrate formation may be 12 hours, 24 hours, 48hours, 60 hours, 72 hours, 100 hours, or 200 hours, for example, underambient conditions. In some embodiments, fibril growth may occur almostimmediately post nonwoven production.

Typical size scale of fibril or flake or other surface structuresprotruding from surface due to blooming may be of the order of fewnanometers to few tens of micrometers. For example, the average lengthof the bloomed surface structures can range from about 5 nanometers toabout 50 micrometers, from about 100 nanometers to about 30 micrometers,or from about 500 nanometers to about 20 micrometers. Preferred averagewidth of the bloomed surface structures can range from about 5nanometers to about 50 micrometers, from about 100 nanometers to about20 micrometers, or from about 500 nanometers to about 5 micrometers.Preferred average thickness of the bloomed surface structures wouldrange from about 5 nanometers to about 10 micrometers, more preferablyfrom about 50 nanometers to about 5 micrometers, and most preferablyfrom about 100 nanometers to about 1 micrometers. Preferred averagehydraulic diameter, calculated as 4*(Cross-sectionalArea)/(Cross-sectional Perimeter) of the bloomed surface structure canrange from about 5 nanometers to about 20 micrometers, from about 50nanometers to about 10 micrometers, or from about 100 nanometers toabout 1.5 micrometers. In a specific embodiment, the average hydraulicdiameter of a fibril is in the range of from about 100 nanometers toabout 800 nanometers. Average separation of the bloomed surfacestructures from one another can range from about 100 nanometers to about20 micrometers, from about 500 nanometers to about 10 micrometers, orfrom about 500 nanometers to about 5 micrometers.

The crimped fiber spunbond nonwoven webs of the present disclosure orcrimped fiber spunbond nonwoven laminates of the present disclosure thathave at least one layer comprising fibers comprising fibrils may beconfigured to be softer or harder than, or have the same softness as,conventional nonwoven laminates and/or may have a rougher, smoother, orthe same tactile property as compared to conventional nonwovensubstrates. The softness, hardness, and/or tactile property of thenonwoven substrates may vary depending on the type and amount of lipidesters present in the composition used to form the fibers and the lengthof the fibrils, for example. The softness, hardness, and/or texture mayalso vary depending on where the one or more layers of fibers havingfibrils are positioned within a nonwoven substrate.

The additive may be applied at a basis weight of from about 0.1 gsm to10 gsm, preferably <1 gsm or alternatively 0.4 percent by weight. Theadditive may be blended with other melt additive or topical ingredients,for example in a lotion composition. For those forms where bi-componentfibers are utilized, the additive may be present at the same level ineach of the constituents of the bi-component fiber, may be at differentlevels with regard to the constituents of the bi-component fiber, or maybe preset in one constituent but not the other of a bi-component fiber.

For those forms where the hydrophobic additive is provided as a meltadditive, e.g. part of the master batch, preferably between 0.5 percentby weight to about 20 percent by weight, preferably less than 10 percentby weight or any range within these values or any value within theseranges.

The additive may be applied to the fibers of the nonwoven laminates ofthe present invention by any suitable process. Some examples includespraying, slot coating, or the like. Other suitable hydrophobicadditives are available from Techmer PM, LLC.

Examples

FIG. 17 is an SEM photo of a polypropylene fiber with glyceroltristearate additive added to the fibers as a master batch (8 wt %Techmer PPM17000 High Load Hydrophobic). The masterbatch comprised about60 percent by weight polypropylene and about 40 percent by weightglycerol tristearate. As shown the fiber 991 comprise a plurality offibrils 992 extending from the surface thereof. FIG. 18 is an SEM photoof a bi-component fiber 1091 of polyethylene and polypropylene arrangedin 30/70 sheath/core configuration—the polyethylene being the sheath.The additive (glycerol tristearate) was added to the fibers as a masterbatch. The master batch comprised about 60 percent by weightpolyethylene and about 40 percent by weight glycerol tristearate. Thesheath of the fiber comprised 17 percent by weight master batch and 83percent by weight polyethylene. As shown, the fiber 1091 comprises aplurality of fibrils 1092 extending therefrom. FIG. 19 is an SEM photoof a bi-component fiber 1191 of polyethylene and polypropylene arrangedin 30/70 sheath/core configuration—polyethylene being the sheath. Theadditive (glycerol tristearate) was added to the fibers as a masterbatch. The master batch comprised about 60 percent by weightpolyethylene and about 40 percent by weight glycerol tristearate. Thesheath of the fiber comprised 30 percent by weight master batch and 70percent by weight polyethylene. As shown, the fiber 1191 comprises aplurality of fibrils 1192 extending therefrom.

FIGS. 20 and 21 demonstrate that the additive can be added variably withregard to differing components of a fiber. FIG. 20 is an SEM photo of apolypropylene/polyethylene bi-component fiber 1291 where thepolypropylene and the polyethylene are configured side byside—polyethylene 1291A and polypropylene 1291B. The additive was addedat varying levels as a master batch (Techmer PPM17000 High LoadHydrophobic)—10% master batch was added to the polypropylene componentand 5% of the same master batch was added to the polyethylene component.

FIG. 21 is an SEM photo of a polypropylene/polyethylene bi-componentfiber 1391 where the polypropylene and polyethylene are configured sideby side—polypropylene 1391A and polyethylene 1391B comprising fibrils1392. The additive was added at varying levels as a master batch(Techmer PPM17000 High Load Hydrophobic)—16% master batch was added tothe polypropylene component and 8% master batch was added to thepolyethylene component. In some instances, the additive may bloom moreon one side of the bi-component fiber 1391 than the other. FIG. 22 is aphotomicrograph showing a plurality of fibers of a nonwoven where theadditive has been applied post fiber production. As shown, the additiveforms a plurality of droplets/particles 1492 on the surface of thefibers 1491.

FIGS. 23 and 24 are SEM photos showing fibers comprising a meltadditive. In FIG. 23, the additive has bloomed to the surface of thefibers to form a film, and in FIG. 24, the additive has bloomed to thesurface of the fiber to form a film/fibril combination. In FIG. 24, thefibers are bi-component polypropylene/polyethylene fibers in a side byside configuration. The polypropylene comprises 16 percent by weightmaster batch (Techmer PPM17000 High Load Hydrophobic), and thepolyethylene component comprises 8 percent by weight of the same masterbatch.

Hydrophilic Additive

As mentioned previously, the first layers described herein, may comprisea hydrophobic additive which blooms on a surface of at least a portionof the first plurality of fibers and/or may comprise an after productionspray on hydrophobic additive. Similarly, the second layer may comprisea hydrophilic additive which can be a portion of the second layer masterblended into the fibers of the second layer or can be subsequently addedon via kiss coating, spraying or any other suitable process.

Any suitable additive can be used. Some suitable examples include:Techmer PPM15560; Techmer TPM12713; Polyvel VW351 PP Wetting Agent;Goulston Hydrosorb 1001; as well as those hydrophilic additive disclosedin US Patent Application Publication No. 2012/0077886. Some suitableexamples of post formation additives include Silastol PH26, PHP90 orPST-N available from Schill & Seilacher, or Stantex 56327 available fromPulcra Chemicals GmbH.

Example

FIG. 25 is an SEM photo showing fibers comprising a hydrophilic meltadditive. The fibers depicted are polypropylene/polypropylene side byside (70/30) configured bi-component fibers. Both of the polypropylenecomponents comprised 2.0% Techmer TPM12713 hydrophilic masterbatch, andthe first component additionally comprised 1.0% of TiO₂ masterbatch(MBWhite009). As shown, the hydrophilic additive appears to form novisible structure as opposed to forming fibrils as provided with regardto the hydrophobic melt additive disclosed above.

Additional forms are contemplated where the nonwoven webs includecompositions in addition to the hydrophobic or hydrophilic additive.Some examples include lotions, skin care actives, odor absorbing orinhibiting or masking, fragrances, pigments, dyes, agents affecting thecoefficient of friction, antimicrobial/antibacterial agents, the like orcombinations thereof.

Opacity

The opacity of the crimped fiber spunbond nonwoven webs may differ fromthe opacity of adjacent layers of an absorbent article. In someinstances, the crimped fiber spunbond nonwoven web may form awearer-facing surface which is closest to an external observer. In suchinstances, the crimped fiber spunbond nonwoven web may have a loweropacity than an underlying layer in order to maximize observablecontrast differences between the layers and/or to observe printing orcolored adhesives. In some forms, the crimped fiber spunbond nonwovenwebs may have a low opacity in the context of an absorbent article outercover such that graphics on subjacent layers may be visibletherethrough.

Alternatively, the crimped fiber spunbond nonwoven web as part of thewearer-facing surface may have a higher opacity than an underlying layerin order to more effectively mask bodily exudates (e.g., urine, menses,or BM) or to provide for greater color contrast with the layers below.When a crimped fiber spunbond nonwoven web is used as a fluid-permeabletopsheet, the layer closest to an external observer would be thewearer-facing surface. In a form, where the crimped fiber spunbondnonwoven web is located on the external surface of an absorbent article(e.g., an outer cover, fastening system element, stretch ear, belt, orside panel), the layer closest to an external observer would be thegarment-facing surface.

As noted, crimped fiber spunbond nonwoven web of the present inventionmay have a high opacity. This enables an aperture pattern to be moreeasily distinguished, provides contrast to any colors and materialsunderneath, and in the case of a diaper topsheet or a sanitary napkintopsheet, masks the presence of bodily fluids contained within theabsorbent core, providing a cleaner appearance to the wearer. To achievethis benefit, opacities of greater than about 30, about 40, about 50, orabout 60 may be desired. In some forms of the present invention,opacities may range from about 40-100 or from about 50-90, specificallyreciting all values within these ranges and any ranges created thereby.

Increases in opacity can be achieved via any known suitableproduct/process. Some suitable examples include adding fillers (e.g.TiO₂), fiber shape (e.g. Trilobal vs. round), smaller fiber diameters(including microfibers and/or nano fibers), etc. A specific example ofnonwoven web having high opacity is an SMS (spunbond, meltblown,spunbond) or an SMNS (spunbond, meltblown, nano fiber, spunbond)construction. Another specific example is a nonwoven comprising nanofibers, such as those produced by melt film fibrillation as described inU.S. Pat. No. 8,487,156 and U.S. Patent Application Publication No.2004/0266300. In one specific example, the web of the invention maycomprise a layer having meltblown and nanofibers—SMNS construction.

Disposable Absorbent Articles

Disposable absorbent articles of the present invention may utilize thecrimped fiber spunbond nonwoven webs/laminates described herein in anysuitable location. And, the crimped fiber spunbond nonwovenwebs/laminates described herein may be incorporated into any suitabledisposable absorbent article. Some suitable examples of absorbentarticles include diapers, including taped diapers—refastenable; diaperpants—pre-fastened refastenable or pre-fastened non-refastenable;feminine sanitary napkins; tampons; adult incontinence products, e.g.pants or pads; baby wipes, sanitary wipes, cleansing wipes, and/or thelike. Some suitable uses for the crimped fiber spunbond nonwoven webs ofthe present invention in some absorbent articles include a topsheet, abacksheet, a secondary layer between the topsheet and backsheet, etc.

Referring to FIG. 26, an absorbent article 1810 which may utilize thecrimped fiber spunbond nonwoven webs/laminates described herein may be asanitary napkin/feminine hygiene pad. As shown, the sanitary napkin 1810may comprise a liquid permeable topsheet 1814, a liquid impermeable, orsubstantially liquid impermeable, backsheet 1816, and an absorbent core1818 positioned intermediate the topsheet 1814 and the backsheet 1816.The sanitary napkin 1810 may comprise wings 1820 extending outwardlywith respect to a longitudinal axis 1880 of the sanitary napkin 1810.The sanitary napkin 1810 may also comprise a lateral axis 1890. Thewings 1820 may be joined to the topsheet 1814, the backsheet 1816,and/or the absorbent core 1818. The sanitary napkin 1810 may alsocomprise a front edge 1822, a rear edge 1824 longitudinally opposing thefront edge 1822, a first side edge 1826, and a second side edge 1828laterally opposing the first side edge 1826. The longitudinal axis 1880may extend from a midpoint of the front edge 1822 to a midpoint of therear edge 1824. The lateral axis 1890 may extend from a midpoint of thefirst side edge 1828 to a midpoint of the second side edge 1828. Thesanitary napkin 1810 may also be provided with additional featurescommonly found in sanitary napkins as is known in the art. In some formsof the present invention, the wings may be provided with zones ofextensibility as described in U.S. Pat. No. 5,972,806.

Any suitable absorbent core known in the art may be utilized. Theabsorbent core 1818 may be any absorbent member which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine, menses, and/orother body exudates. The absorbent core 1818 may be manufactured from awide variety of liquid-absorbent materials commonly used in disposableabsorbent articles such as comminuted wood pulp which is generallyreferred to as airfelt. The absorbent core 1818 may comprisesuperabsorbent polymers (SAP) and less than 15%, less than 10%, lessthan 5%, less than 3%, or less than 1% of airfelt, or be completely freeof airfelt. Examples of other suitable absorbent materials comprisecreped cellulose wadding, meltblown polymers including coform,chemically stiffened, modified or cross-linked cellulosic fibers, tissueincluding tissue wraps and tissue laminates, absorbent foams, absorbentsponges, superabsorbent polymers, absorbent gelling materials, or anyequivalent material or combinations of materials.

The configuration and construction of the absorbent core 1818 may vary(e.g., the absorbent core may have varying caliper zones, a hydrophilicgradient, a superabsorbent gradient, or lower average density and loweraverage basis weight acquisition zones; or may comprise one or morelayers or structures). In some forms, the absorbent core 1818 maycomprise one or more channels, such as two, three, four, five, or sixchannels.

The absorbent core 1818 of the present disclosure may comprise one ormore adhesives, for example, to help immobilize the SAP or otherabsorbent materials within a core wrap and/or to ensure integrity of thecore wrap, in particular when the core wrap is made of two or moresubstrates. The core wrap may extend to a larger area than required forcontaining the absorbent material(s) within.

Absorbent cores comprising relatively high amounts of SAP with variouscore designs are disclosed in U.S. Pat. No. 5,599,335 to Goldman et al.,EP 1,447,066 to Busam et al., WO 95/11652 to Tanzer et al., U.S. Pat.Publ. No. 2008/0312622A1 to Hundorf et al., and WO 2012/052172 to VanMalderen.

Other forms and more details regarding channels and pockets that arefree of, or substantially free of absorbent materials, such as SAP,within absorbent cores are discussed in greater detail in U.S. PatentApplication Publication Nos. 2014/0163500, 2014/0163506, and2014/0163511, all published on Jun. 12, 2014.

The absorbent article 1810 may comprise additional layers between thetopsheet 1814 and the absorbent core 1818. For example, the absorbentarticle 1810 may comprise a secondary topsheet and/or an acquisitionlayer positioned between the topsheet 1814 and the absorbent core 1818.

The backsheet can comprise a liquid impervious film. The backsheet canbe impervious to liquids (e.g., body fluids) and can be typicallymanufactured from a thin plastic film. However, typically the backsheetcan permit vapours to escape from the disposable article. In anembodiment, a microporous polyethylene film can be used for thebacksheet. A suitable microporous polyethylene film is manufactured byMitsui Toatsu Chemicals, Inc., Nagoya, Japan and marketed in the tradeas PG-P.

One suitable material for the backsheet can be a liquid imperviousthermoplastic film having a thickness of from about 0.012 mm (0.50 mil)to about 0.051 mm (2.0 mils), for example including polyethylene orpolypropylene. Typically, the backsheet can have a basis weight of fromabout 5 g/m² to about 35 g/m². However, it should be noted that otherflexible liquid impervious materials may be used as the backsheet.Herein, “flexible” refers to materials which are compliant and whichwill readily conform to the general shape and contours of the wearer'sbody.

The backsheet can be typically positioned adjacent an outer-facingsurface of the absorbent core and can be joined thereto by any suitableattachment device known in the art. For example, the backsheet may besecured to the absorbent core by a uniform continuous layer of adhesive,a patterned layer of adhesive, or an array of separate lines, spirals,or spots of adhesive. Illustrative, but non-limiting adhesives, includeadhesives manufactured by H. B. Fuller Company of St. Paul, Minn.,U.S.A., and marketed as HL-1358J. An example of a suitable attachmentdevice including an open pattern network of filaments of adhesive isdisclosed in U.S. Pat. No. 4,573,986 entitled “DisposableWaste-Containment Garment”, which issued to Minetola et al. on Mar. 4,1986. Another suitable attachment device including several lines ofadhesive filaments swirled into a spiral pattern is illustrated by theapparatus and methods shown in U.S. Pat. No. 3,911,173 issued toSprague, Jr. on Oct. 7, 1975; U.S. Pat. No. 4,785,996 issued to Ziecker,et al. on Nov. 22, 1978; and U.S. Pat. No. 4,842,666 issued to Wereniczon Jun. 27, 1989. Alternatively, the attachment device may include heatbonds, thermal fusion bonds, pressure bonds, ultrasonic bonds, dynamicmechanical bonds, or any other suitable attachment device orcombinations of these attachment devices. The backsheet may beadditionally secured to the topsheet by any of the above-citedattachment devices/methods.

The topsheet may comprise the crimped fiber spunbond nonwonven web orcrimped fiber spunbond nonwoven laminates described herein. Options forutilization of the crimped fiber spundonb nonwoven webs/laminatesdescribed herein as topsheets are discussed hereafter.

Still another example of a disposable absorbent article which mayutilize the crimped fiber spunbond nonwoven webs/laminates of thepresent invention are diapers which include non-refastenable pantsand/or re-fastenable diapers. Diapers have can have a similarconstruction to that of sanitary napkins. An exemplary diaper isdescribed below.

Referring to FIG. 27, a plan view of an example absorbent article thatis a diaper 20 in its flat-out, uncontracted state (i.e., with elasticinduced contraction pulled out) with portions of the structure beingcut-away to more clearly show the construction of the diaper 20 and withits wearer-facing surface toward the viewer. This diaper is shown forillustration purpose only as the present disclosure may be used formaking a wide variety of diapers and other absorbent articles.

The absorbent article may comprise a liquid permeable topsheet 24, aliquid impermeable backsheet 25, an absorbent core 28 positioned atleast partially intermediate the topsheet 24 and the backsheet 25, andbarrier leg cuffs 34. The absorbent article may also comprise a liquidmanagement system (“LMS”) 50 (shown in FIG. 28), which, in the examplerepresented, comprises a distribution layer 54 and an acquisition layer52 that will both be further discussed below. In various forms, theacquisition layer 52 may instead distribute bodily exudates and thedistribution layer 54 may instead acquire bodily exudates or both layersmay distribute and/or acquire bodily exudates. The LMS 50 may also beprovided as a single layer or two or more layers. The absorbent articlemay also comprise elasticized gasketing cuffs 32 joined to the chassisof the absorbent article, typically via the topsheet and/or backsheet,and substantially planar with the chassis of the diaper.

The Figures also show typical taped diaper components such as afastening system comprising adhesive tabs 42 or other mechanicalfasteners attached towards the rear edge of the absorbent article 20 andcooperating with a landing zone 44 on the front of the absorbent article20. The absorbent article may also comprise other typical elements,which are not represented, such as a rear elastic waist feature and afront elastic waist feature, for example.

The absorbent article 20 may comprise a front waist edge 10, a rearwaist edge 12 longitudinally opposing the front waist edge 10, a firstside edge 3, and a second side edge 4 laterally opposing the first sideedge 3. The front waist edge 10 is the edge of the absorbent article 20which is intended to be placed towards the front of the user when worn,and the rear waist edge 12 is the opposite edge. Together the frontwaist edge 10 and the rear waist edge form waist opening when theabsorbent article 20 is donned on a wearer. The absorbent article 20 mayhave a longitudinal axis 80 extending from the lateral midpoint of thefront waist edge 10 to a lateral midpoint of the rear waist edge 12 ofthe absorbent article 20 and dividing the absorbent article 20 in twosubstantially symmetrical halves relative to the longitudinal axis 80,with article placed flat and viewed from the wearer-facing surface asillustrated FIG. 27. The absorbent article may also have a lateral axis90 extending from the longitudinal midpoint of the first side edge 3 tothe longitudinal midpoint of the second side edge 4. The length L of theabsorbent article 20 may be measured along the longitudinal axis 80 fromthe front waist edge 10 to the rear waist edge 12. The crotch width ofthe absorbent article 20 may be measured along the lateral axis 90 fromthe first side edge 3 to the second side edge 4. The absorbent article20 may comprise a front waist region 5, a rear waist region 6, and acrotch region 7. The front waist region, the rear waist region, and thecrotch region each define ⅓ of the longitudinal length of the absorbentarticle. Front and back portions may also be defined on opposite sidesof the lateral axis 90.

The topsheet 24, the backsheet 25, the absorbent core 28, and the otherarticle components may be assembled in a variety of configurations, inparticular by gluing or heat embossing, for example. Example diaperconfigurations are described generally in U.S. Pat. Nos. 3,860,003,5,221,274, 5,554,145, 5,569,234, 5,580,411, and 6,004,306.

The absorbent core 28 may comprise an absorbent material comprising 75%to 100%, at least 80%, at least 85%, at least 90%, at least 95%, or atleast 99%, all by weight, of the absorbent material, specificallyreciting all 0.1% increments within the above-specified ranges and allranges formed therein or thereby, and a core wrap enclosing theabsorbent material. The core wrap may typically comprise two materials,substrates, or nonwoven materials 16 and 16′ for the top side and bottomside of the core.

The absorbent core 28 may comprises one or more channels, represented inFIG. 27 as the four channels 26, 26′ and 27, 27′. Additionally oralternative, the LMS 50 may comprises one or more channels, representedin FIGS. 27-29 as channels 49, 49′. In some forms, the channels of theLMS 50 may be positioned within the absorbent article 20 such theyaligned with, substantially aligned with, overlap, or at least partiallyoverlap, the channels of the absorbent core 28. These and othercomponents of the absorbent articles will now be discussed in moredetails.

The topsheet 24 is the part of the absorbent article that is directly incontact with the wearer's skin. The topsheet 24 may be joined to thebacksheet 25, the core 28 and/or any other layers as is known to thoseof skill in the art. Usually, the topsheet 24 and the backsheet 25 arejoined directly to each other in some locations (e.g., on or close tothe periphery of the article) and are indirectly joined together inother locations by directly joining them to one or more other elementsof the absorbent article 20.

The backsheet 25 is generally that portion of the absorbent article 20positioned adjacent the garment-facing surface of the absorbent core 28and which prevents, or at least inhibits, the bodily exudates absorbedand contained therein from soiling articles such as bedsheets andundergarments. The backsheet 25 is typically impermeable, or at leastsubstantially impermeable, to liquids (e.g., urine, running BM), butpermeable to vapors to allow the diaper to “breath”. The backsheet may,for example, be or comprise a thin plastic film such as a thermoplasticfilm having a thickness of about 0.012 mm to about 0.051 mm. Examplebacksheet films include those manufactured by Tredegar Corporation,based in Richmond, Va., and sold under the trade name CPC2 film. Othersuitable backsheet materials may include breathable materials whichpermit vapors to escape from the absorbent article 20 while stillpreventing, or at least inhibiting, bodily exudates from passing throughthe backsheet 25. Example breathable materials may include materialssuch as woven webs, nonwoven webs, and composite materials such asfilm-coated nonwoven webs, microporous films, and monolithic films.

The backsheet 25 may be joined to the topsheet 24, the absorbent core28, and/or any other element of the absorbent article 20 by anyattachment methods known to those of skill in the art. Suitableattachment methods are described above with respect to methods forjoining the topsheet 24 to other elements of the absorbent article 20.

As used herein, the term “absorbent core” refers to the individualcomponent of the absorbent article having the most absorbent capacityand that comprises an absorbent material. The absorbent core maycomprise a core wrap or core bag (hereafter “core wrap”) enclosing theabsorbent material. The term “absorbent core” does not include the LMSor any other component of the absorbent article which is not eitherintegral part of the core wrap or placed within the core wrap. Theabsorbent core may comprise, consist essentially of, or consist of, acore wrap, absorbent material as defined below, and glue enclosed withinthe core wrap. Pulp or air-felt may also be present within the core wrapand may form a portion of the absorbent material. The absorbent coreperiphery, which may be the periphery of the core wrap, may define anysuitable shape, such as a “T,” “Y,” “hour-glass,” or “dog-bone” shape,for example. An absorbent core periphery having a generally “dog bone”or “hour-glass” shape may taper along its width towards the middle or“crotch” region of the core. In this way, the absorbent core may have arelatively narrow width in an area of the absorbent core intended to beplaced in the crotch region of an absorbent article.

The absorbent core 28 of the present disclosure may comprise anabsorbent material with a high amount of superabsorbent polymers (hereinabbreviated as “SAP”) enclosed within a core wrap. The SAP content mayrepresent 70% to 100% or at least 70%, 75%, 80%, 85%, 90%, 95%, 99%, or100% by weight of the absorbent material contained in the core wrap. TheSAP useful with the present disclosure may include a variety ofwater-insoluble, but water-swellable polymers capable of absorbing largequantities of fluids. The core wrap is not considered as absorbentmaterial for the purpose of assessing the percentage of SAP in theabsorbent core. The remainder of the absorbent material in the core 28may be air-felt.

“Absorbent material” means a material which has some absorbency propertyor liquid retaining properties, such as SAP, cellulosic fibers as wellas synthetic fibers. Typically, glues used in making absorbent coreshave no absorbency properties and are not considered as absorbentmaterial. The SAP content may be higher than 80%, for example at least85%, at least 90%, at least 95%, at least 99%, and even up to andincluding 100% of the weight of the absorbent material contained withinthe core wrap, as stated above. This provides a relatively thin corecompared to conventional cores typically comprising between 40-60% SAP,for example, and high content of cellulose fibers or airfelt. Theabsorbent material may comprise less than 15% or less than 10% weightpercent of natural or synthetic fibers, less than 5% weight percent,less than 3% weight percent, less than 2% weight percent, less than 1%weight percent, or may even be substantially free of, or free of,natural and/or synthetic fibers, specifically reciting all 0.1%increments within the specified ranges and all ranges formed therein orthereby. The absorbent material may comprise little or no airfelt(cellulose) fibers, in particular the absorbent core may comprise lessthan 15%, 10%, 5%, 3%, 2%, 1% airfelt (cellulose) fibers by weight, ormay even be substantially free of, or free of, cellulose fibers,specifically reciting all 0.1% increments within the specified rangesand all ranges formed therein or thereby.

The absorbent core 28 may also comprise a generally planar top side anda generally planar bottom side. The core 28 may have a longitudinal axis80′ corresponding substantially to the longitudinal axis 80 of theabsorbent article, as seen from the top in a planar view as in FIG. 19.The absorbent material may be distributed in higher amount towards thefront side than towards the rear side as more absorbency may be requiredat the front in particular articles. The absorbent material may have anon-uniform basis weight or a uniform basis weight across any portion ofthe core. The core wrap may be formed by two nonwoven materials,substrates, laminates, or other materials, 16, 16′ which may be at leastpartially sealed along the sides of the absorbent core. The core wrapmay be at least partially sealed along its front side, rear side, andtwo longitudinal sides so that substantially no absorbent material leaksout of the absorbent core wrap. The first material, substrate, ornonwoven 16 may at least partially surround the second material,substrate, or nonwoven 16′ to form the core wrap. The first material 16may surround a portion of the second material 16′ proximate to the firstand second side edges 284 and 286.

Cores comprising relatively high amount of SAP with various core designsare disclosed in U.S. Pat. No. 5,599,335 (Goldman), EP 1,447,066(Busam), WO 95/11652 (Tanzer), U.S. Pat. Publ. No. 2008/0312622A1(Hundorf), and WO 2012/052172 (Van Malderen).

The absorbent material may be one or more continuous layers presentwithin the core wrap. Alternatively, the absorbent material may becomprised of individual pockets or stripes of absorbent materialenclosed within the core wrap. In the first case, the absorbent materialmay be, for example, obtained by the application of a single continuouslayer of absorbent material. The continuous layer of absorbent material,in particular of SAP, may also be obtained by combining two or moreabsorbent layers having discontinuous absorbent material applicationpattern, wherein the resulting layer is substantially continuouslydistributed across the absorbent particulate polymer material area, asdisclosed in U.S. Pat. Appl. Publ. No. 2008/0312622A1 (Hundorf), forexample. The absorbent core 28 may comprise a first absorbent layer anda second absorbent layer. The first absorbent layer may comprise thefirst material 16 and a first layer 61 of absorbent material, which maybe 100% or less of SAP. The second absorbent layer may comprise thesecond material 16′ and a second layer 62 of absorbent material, whichmay also be 100% or less of SAP.

The fibrous thermoplastic adhesive material 51 may be at least partiallyin contact with the absorbent material 61, 62 in the land areas and atleast partially in contact with the materials 16 and 16′ in the junctionareas. This imparts an essentially three-dimensional structure to thefibrous layer of thermoplastic adhesive material 51, which in itself isessentially a two-dimensional structure of relatively small thickness,as compared to the dimension in length and width directions. Thereby,the fibrous thermoplastic adhesive material may provide cavities tocover the absorbent material in the land area, and thereby immobilizesthis absorbent material, which may be 100% or less of SAP.

The core wrap may be made of a single substrate, material, or nonwovenfolded around the absorbent material, or may comprise two (or more)substrates, materials, or nonwovens which are attached to another.Typical attachments are the so-called C-wrap and/or sandwich wrap. In aC-wrap, the longitudinal and/or transversal edges of one of thesubstrates are folded over the other substrate to form flaps. Theseflaps are then bonded to the external surface of the other substrate,typically by gluing. Other techniques may be used to form a core wrap.For example, the longitudinal and/or transversal edges of the substratesmay be bonded together and then folded underneath the absorbent core 28and bonded in that position.

The core wrap may be at least partially sealed along all the sides ofthe absorbent core so that substantially no absorbent material leaks outof the core. By “substantially no absorbent material” it is meant thatless than 5%, less than 2%, less than 1%, or about 0% by weight ofabsorbent material escape the core wrap. The term “seal” is to beunderstood in a broad sense. The seal does not need to be continuousalong the whole periphery of the core wrap but may be discontinuousalong part or the whole of it, such as formed by a series of seal pointsspaced on a line. A seal may be formed by gluing and/or thermal bonding.

The core wrap may also be formed by a single substrate which may encloseas in a parcel wrap the absorbent material and be sealed along the frontside and rear side of the core and one longitudinal seal.

The absorbent article may comprise a pair of barrier leg cuffs 34. Eachbarrier leg cuff may be formed by a piece of material which is bonded tothe absorbent article so it can extend upwards from the inner surface ofthe absorbent article and provide improved containment of liquids andother bodily exudates approximately at the junction of the torso andlegs of the wearer. The barrier leg cuffs 34 are delimited by a proximaledge 64 joined directly or indirectly to the topsheet 24 and/or thebacksheet 25 and a free terminal edge 66, which is intended to contactand form a seal with the wearer's skin. The barrier leg cuffs 34 extendat least partially between the front waist edge 10 and the rear waistedge 12 of the absorbent article on opposite sides of the longitudinalaxis 80 and are at least present in the crotch region 7. The barrier legcuffs 34 may be joined at the proximal edge 64 with the chassis of theabsorbent article by a bond 65 which may be made by gluing, fusionbonding, or combination of other suitable bonding processes. The bond 65at the proximal edge 64 may be continuous or intermittent. The bond 65closest to the raised section of the leg cuffs 34 delimits the proximaledge 64 of the standing up section of the leg cuffs 34.

The barrier leg cuffs 34 may be integral with the topsheet 24 or thebacksheet 25 or may be a separate material joined to the absorbentarticle's chassis. The material of the barrier leg cuffs 34 may extendthrough the whole length of the diapers but may be “tack bonded” to thetopsheet 24 towards the front waist edge 10 and rear waist edge 12 ofthe absorbent article so that in these sections the barrier leg cuffmaterial remains flush with the topsheet 24.

Each barrier leg cuff 34 may comprise one, two or more elastic strandsor strips of film 35 close to this free terminal edge 66 to provide abetter seal.

In addition to the barrier leg cuffs 34, the absorbent article maycomprise gasketing cuffs 32, which are joined to the chassis of theabsorbent article, in particular to the topsheet 24 and/or the backsheet25 and are placed externally relative to the barrier leg cuffs 34. Thegasketing cuffs 32 may provide a better seal around the thighs of thewearer. Each gasketing leg cuff may comprise one or more elastic stringsor elastic elements in the chassis of the absorbent article between thetopsheet 24 and backsheet 25 in the area of the leg openings. All or aportion of the barrier leg and/or gasketing cuffs may be treated with alotion or skin care composition. The barrier leg cuffs may beconstructed in a number of different configurations, including thosedescribed in U.S. Pat. App. Publ. No. 2012/0277713.

In a form, the absorbent article may comprise front ears 46 and rearears 40. The ears may be an integral part of the chassis, such as formedfrom the topsheet 24 and/or backsheet 25 as side panel. Alternatively,as represented on FIG. 27, the ears (46, 40) may be separate elementsattached by gluing, heat embossing, and/or pressure bonding. The rearears 40 may be stretchable to facilitate the attachment of the tabs 42to the landing zone 44 and maintain the taped diapers in place aroundthe wearer's waist. The rear ears 40 may also be elastic or extensibleto provide a more comfortable and contouring fit by initiallyconformably fitting the absorbent article to the wearer and sustainingthis fit throughout the time of wear well past when absorbent articlehas been loaded with exudates since the elasticized ears allow the sidesof the absorbent article to expand and contract.

One function of the LMS 50 is to quickly acquire the fluid anddistribute it to the absorbent core 28 in an efficient manner. The LMS50 may comprise one or more layers, which may form a unitary layer ormay remain as discrete layers which may be attached to each other. TheLMS 50 may comprise two layers: a distribution layer 54 and anacquisition layer 52 disposed between the absorbent core and thetopsheet, but the present disclosure is not limited to such aconfiguration.

The LMS 50 may comprise SAP as this may slow the acquisition anddistribution of the fluid. In other forms, the LMS may be substantiallyfree (e.g., 80%, 85%, 90%, 95%, or 99% free of) or completely free ofSAP. The LMS may also comprise one or more of a variety of othersuitable types of materials, such as opened-cell foam, air-laid fibers,or carded, resin bonded nonwoven materials, for example. Suitableexample LMSs are described in WO 2000/59430 (Daley), WO 95/10996(Richards), U.S. Pat. No. 5,700,254 (McDowall), and WO 02/067809(Graef), for example.

The LMS 50 may comprise a distribution layer 54. The distribution layer54 may comprise at least 50% or more by weight of cross-linked cellulosefibers, for example. The cross-linked cellulosic fibers may be crimped,twisted, or curled, or a combination thereof including crimped, twisted,and curled. This type of material is disclosed in U.S. Pat. Publ. No.2008/0312622 A1 (Hundorf).

The LMS 50 may alternatively or additionally comprise an acquisitionlayer 52. The acquisition layer 52 may be disposed, for example, betweenthe distribution layer 54 and the topsheet 24. The acquisition layer 52may be or may comprise a non-woven material, such as an SMS or SMMSmaterial, comprising a spunbonded, a melt-blown and a further spunbondedlayer or alternatively a carded chemical-bonded nonwoven. Theacquisition layer 52 may comprise air or wet-laid cellulosic,cross-linked cellulosic, or synthetic fibers, or blends thereof. Theacquisition layer 52 may comprise a roll-stock web of synthetic fibers(which may be processed to increase void space, such as by solid stateformation), or a combination of synthetic and cellulosic fibers, bondedtogether to form a highloft material. Alternatively, the acquisitionlayer 52 may comprise absorbent open cell foam. The nonwoven materialmay be latex bonded.

The LMS 50 of the absorbent article 20 may comprise channels that maygenerally enable better conformation of the absorbent article to thewearer's anatomy, leading to increased freedom-of-movement and reducedgapping. One or more of the channels of the LMS 50 may be configured towork in concert with various channels in the absorbent core 28, asdiscussed above. Furthermore, channels in the LMS 50 may also provideincreased void space to hold and distribute urine, BM or other bodilyexudates within the absorbent article, leading to reduced leakage andskin contact. Channels in the LMS 50 may also provide internalserviceable indicia, especially when highlighted via physicaldifferences in texture, color, and/or pattern, to facilitate achievingthe correct alignment of the absorbent article on a wearer. Thus, suchphysical differences may be, for example, visually and/or tactilelynoticeable.

As stated previously, the crimped fiber spunbond nonwoven webs/laminatesof the present invention may be utilized as a topsheet for a disposableabsorbent article, examples of which include the sanitary napkin 1810and diaper 20 discussed heretofore.

The crimped fiber spunbond nonwoven webs/laminates of the presentdisclosure may be used as components of absorbent articles. More thanone crimped fiber spunbond nonwoven web/laminate may be used in a singleabsorbent article. In such a context, the crimped fiber spunbondnonwoven webs/laminates may form at least a portion of: a topsheet; atopsheet and an acquisition layer; a topsheet and a distribution layer;an acquisition layer and a distribution layer; a topsheet, anacquisition layer, and a distribution layer; an outer cover; abacksheet; an outer cover and a backsheet, wherein a film (non-aperturedlayer) forms the backsheet and a crimped fiber spunbond nonwovenweb/laminate forms the outer cover; a leg cuff; an ear or side panel; afastener; a waist band; belt or any other suitable portion of anabsorbent article. The number of layers in a crimped fiber spunbondnonwoven laminate may also be determined by the nonwoven laminates'particular use.

In some forms, additional layers may be positioned between the topsheetand the absorbent core. For example, a secondary topsheet, acquisitionlayer, and/or distribution layer, each of which are known in the art,may be positioned between the topsheet and the absorbent core of theabsorbent article.

Forms of the present invention are contemplated where webs of thepresent invention comprise structures as described herein in thenegative Z-direction. In such forms, the urging of the material of theweb in the negative Z-direction may fracture material of an absorbentcore or a portion thereof. As shown in FIG. 82, a sanitary pad, orportion thereof, may comprise the web 8914, an absorbent material 8918,and a support layer 8916. As shown, the structures described herein maycause fracturing of the absorbent material 8918, particularly where theabsorbent material comprises a high internal phase emulsion foam.However, other forms of the invention are contemplated where theabsorbent material 8918 comprises SAP. Still in other forms, the web8914 may comprise the topsheet, the absorbent material 8918 may comprisea first liquid retention layer, and the support layer 8916 may comprisea secondary topsheet or acquisition layer. In such forms, additionalabsorbent cores in addition to a backsheet may be provided.

Forms of the present invention are contemplated where the absorbentmaterial 8918 and the support layer 8916 comprise a heterogeneous mass.The heterogeneous mass along with the absorbent material 8918 andsupport layer 8916 are further described in U.S. Provisional PatentApplication Publication No. 62/118,232.

As shown, the web 8914 comprises a crimped fiber spunbond nonwoven webhaving 2.0 denier per filament polypropylene/polypropylene 70/30bi-component fibers. Any suitable crimped fiber spunbond nonwoven webmay be utilized. The support layer 8916 may comprise any suitablematerial. For example, in some forms, the support layer 8916 maycomprise a spunlaced nonwoven web.

The depressions in the apertured web 8914 and absorbent material 8918may extend through the thickness of the absorbent material 8918 suchthat a plurality of discrete pieces of absorbent material are produced.In other forms, the depressions in the apertured web 8914 and theabsorbent material 8918 may only partially extend through the thicknessof the absorbent material 8916 such that absorbent material remains acontinuous element.

High internal phase emulsion foams are known in the art. Methods ofmaking high internal phase emulsion foams are described in U.S. Pat. No.5,149,720 (DesMarais et al), issued Sep. 22, 1992; U.S. Pat. No.5,827,909 (DesMarais) issued Oct. 27, 1998; and U.S. Pat. No. 6,369,121(Catalfamo et al.) issued Apr. 9, 2002.

Aperturing and Patterns Thereof

As previously disclosed, the first layer may comprise apertures whilethe second layer is sans apertures. In other forms both the first andsecond layers may comprise apertures. And, for those forms with morethan two layers, a plurality of layers of the crimped fiber spunbondnonwoven laminate may comprise apertures. For those forms whereapertures are present, the apertures may be arranged in patterns formingdesigns, shapes, etc.—apertured indicia. In other forms, the aperturesmay be arranged in rows/columns which may be staggered or may not bestaggered from adjacent column/row to adjacent column/row. And recall,that in some forms, a crimped fiber spunbond web may comprise aperturesand may be joined with additional layers in a disposable absorbentarticle.

The apertures in at least one or more layers of a crimped fiber spunbondnonwoven laminate or in a crimped fiber spunbond nonwoven web asdescribed herein, may be grouped in spaced arrays of apertures (seee.g., FIGS. 30-33). An aperture array includes two or more apertureshaving much closer spacing between the apertures than the distancebetween the aperture arrays. The distance between the array and otherapertures is at least about 1.5, at least about 2 times, or at leastabout 3 times the maximum distance between apertures in the array. Fourexamples of nonwoven laminates 2200 of the present invention comprisingpatterned apertures are illustrated in FIGS. 30-33. As illustrated, thenonwoven laminate 2200 may take on a number of configurations. Theapertures are labeled 2212 and the land areas (non-apertured areas) arelabeled 2214. A number of additional example aperture patternconfigurations are illustrated in subsequent figures.

The aperture arrays may form a regular or recognizable shape, such as aheart shape, polygon, ellipse, arrow, chevron, and/or other shapes knownin the pattern art. The apertures arrays may differ in one portion ofthe nonwoven laminate compared to another portion of the nonwovenlaminate. In an absorbent article context, the aperture arrays maydiffer in one region of the absorbent article compared to another regionof the absorbent article. Additionally, the aperture arrays may becoordinated in regions of the absorbent article where the aperturearrays are present. The aperture arrays may be concave, convex, or mayinclude concavities and convexities. The aperture arrays may beorganized into “macro-arrays” having a higher order structure. Forexample, referring to FIGS. 35-48, a nonwoven laminate 2600 of thepresent invention is illustrated with aperture arrays 2602 that may beseparated by a continuous, inter-connected land area pattern 2604. Insuch an instance, the land area pattern 2604 may function as a fluiddistribution pathway and the aperture arrays 2602 may function as fluid“drains” thereby promoting fluid access to the underlying absorbentmaterial or absorbent core. The shape of the aperture arrays may enhancethe ability of the arrays to manage fluid, such as bodily exudates(i.e., urine, runny BM, menses). For example, aperture arrays includinga concavity facing a fluid insult location in an absorbent article mayfunction as fluid collection “traps” as the fluid may travel along the“land area” in the concavity to a point where the concavity ends. Atthis location, the fluid may enter the apertures in the direction of thefluid path or those on either side of the concavity if the fluid turnsin either lateral direction. Example aperture array shapes having aconcavity include heart shapes, star shapes, some polygons, crescents,and chevrons, to name a few examples.

In some forms, apertures, or arrays thereof, in a nonwoven laminate2600, may form one or more continuous or semi-continuous patterns 2606,resulting in discrete “macro” land areas 2608. In such an instance, thediscrete macro land areas 2608 may function as fluid deposition regions.Fluid moving from the discrete macro land areas 2608 in any directionmay be absorbed into the apertures of the continuous or semi-continuouspattern 2606.

In some forms, the apertures, or aperture arrays thereof, in a nonwovenlaminate 2600 may form linear patterns alternating with continuous orsemi-continuous land areas. The nonwoven laminate may includeunidirectional or multi-directional (and intersecting) aperture oraperture array patterns. Linear aperture or array patterns may beoriented parallel to the longitudinal or lateral axis, or at an anglebetween 0 and 90 degrees, specifically reciting all 0.5 degreeincrements within the specified range and all ranges formed therein,from either the longitudinal or lateral axis. Linear apertures oraperture array patterns may function to restrict fluid movement alongthe nonwoven laminate to a greater degree in one direction compared toanother direction. Apertures for nonwoven webs may be similarlyconfigured.

Still referring to FIGS. 35-48, a nonwoven laminate 2600 may comprise anarray of apertures comprising a plurality of patterns 2610A and 2610Bwith continuous or semi-continuous land areas. As shown, a first pattern2610A may comprise apertures which are oriented in a direction which isgenerally parallel to a machine direction 1675 (shown in FIG. 34) aswell as apertures which are oriented at multiple angles with respect tothe machine direction. Similarly, a second pattern 2610B may compriseapertures which are oriented at multiple angles with respect to themachine direction 1675 as well as apertures which are generally parallelto the machine direction 1675. As shown, the apertures of the firstpattern 2610A and/or the second pattern 2610B may be of differentlengths, different angles with respect to the machine direction 1675,and/or different Effective Aperture AREAs.

Additionally, at least one or a plurality of apertures in the firstpattern 2610A may be substantially enclosed by the second pattern 2610B.For example, the second pattern may form a quilt like pattern, e.g.diamond shaped boundaries or any other suitable shape, with the firstpattern disposed within the second pattern thereby forming a unit. Thecombination of the first pattern and the second pattern may repeat sothat there are a plurality of units. Additionally, the first patternwithin the second pattern may be different from one unit to the next.Additional patterns may be utilized. The apertures angled with respectto the machine direction 1675 are believed to aid in fluidacquisition/distribution. For example, fluid moving along the nonwovenlaminate 2600 in the machine direction 1675 may be diverted, in part,because of the angled apertures.

Referring to additionally to FIG. 34, as noted previously, the firstpattern 2610A and/or the second pattern 2610B may comprise a pluralityof apertures of which at least a portion are angled with respect to themachine direction 1675 at a first angle 1680 and another portion areangled with respect to the machine direction 1675 at a second angle1682. The first angle 1680 and the second angle 1682 may be differentfrom one another. In some forms, the second angle 1682 may be the mirrorimage of the first angle 1680. For example, the first angle may be about30 degrees from an axis parallel to the machine direction 1675 while asecond angle is −30 degrees from the axis parallel to the machinedirection 1675. Similarly, the first pattern 2610A and/or the secondpattern 2610B may comprise a plurality of apertures which are orientedgenerally parallel to the machine direction 1675. As mentionedpreviously, apertures which are oriented generally parallel to themachine direction 1675 generally have a lower aspect ratio and largerEffective Aperture AREA (described hereafter) as opposed to thoseapertures which are angled with respect to the machine direction 1675.It is believed that those apertures with increased Effective ApertureAREA allow for quicker fluid acquisitions time. While any suitable anglemay be utilized, as discussed hereafter, once the first angle 1680 andthe second angle 1682 are increased beyond 45 degrees from the machinedirection 1675, the forces of the cross-direction 1677 stretching actmore along the long axis of the aperture than perpendicular thereto. So,apertures which are angled more than 45 degrees with respect to themachine direction 1675 typically comprise less Effective Aperture AREAthan those which are angled to a lesser extent with respect to themachine direction 1675.

As stated previously, the angled apertures are believed to provideadditional fluid handling benefits for the nonwoven laminate 2600 forexample a decrease in fluid run-off. In some forms, greater than about10 percent of the apertures are angled with respect to the machinedirection 1675. Additional forms are contemplated where greater thanabout 20 percent, greater than about 30 percent, greater than about 40percent, greater than about 50 percent, greater than about 60 percent,greater than about 70 percent, greater than about 80 percent and/or lessthan 100 percent, less than about 95 percent, less than about 90percent, less than about 85 percent of the apertures are angled withrespect to the machine direction 1675 including any number or any rangesencompassed by the foregoing values.

Referring still to FIGS. 35-48, the population density of angledapertures may be greater nearer a centerline 1690 of the nonwovenlaminate 2600. For example, spacing between adjacent apertures near thecenterline 1690 may be a first distance while spacing between adjacentapertures further away from the centerline 1690 may be a seconddistance. The first distance may be less than the second distance. As anexample, spacing between adjacent apertures can be about 1 mm. As such,the first distance may be about 1 mm while the second distance may beabout 3 mm or greater. Additional embodiments are contemplated where thedistance between adjacent apertures increases with increasing distancefrom the centerline.

Additionally, in some instances, apertures nearer the centerline 1690may be angled at the first angle 1680 while apertures further from thecenterline 1690 are positioned at the second angle 1682. The first angle1680 may be greater than the second angle 1682 with respect to thecenterline 1690. For, example, the apertures further from the centerline1690 may be oriented such that they are generally parallel to thecenterline 1690 while the apertures positioned closer to the centerline1690 are angled with respect to the centerline 1690. In someembodiments, the angle at which apertures are positioned relative to thecenterline 1690 may decrease as the distance from the centerline 1690increases. For example, a first aperture adjacent the centerline 1690may be oriented at a first angle of 30 degrees with respect to thecenterline 1690, while a second aperture 1 mm from the centerline 1690may be oriented at 20 degrees from the centerline. The aperturespositioned furthest away from the centerline 1690 may be generallyparallel to the centerline 1690. Additional configurations arecontemplated where apertures near the centerline 1690 are angled to alesser extent than those further from the centerline 1690. In someforms, the apertures near the centerline 1690 may be generally parallelto the centerline 1690 while the apertures further from the centerline1690 are angled with respect to the machine direction 1675.

As stated previously the lengths of the apertures may vary as well. Inconjunction with being angled as disclosed above or independentlytherefrom, in some forms, the apertures adjacent the centerline 1690 maybe longer than those which are further away from the centerline 1690.Similarly, the size of the apertures may vary. Variances in aperturesize (Effective Aperture AREA) may be employed in conjunction with thevariation of aperture angle and/or the variation in aperture length, orvariances in aperture size may be employed independently of thevariation of aperture angle and/or variation in aperture length. Forthose embodiments where aperture size may vary, larger apertures may bepositioned adjacent the centerline 1690 while apertures having a smallerEffective Aperture AREA are positioned further away from the centerline1690. For example, apertures adjacent the centerline 1690 may have anEffective Aperture AREA of 15 square millimeters while apertures furtheraway from the centerline may have less Effective Aperture AREA, e.g. 1.0square mm. Any of the values/ranges of Effective Aperture AREA providedherein may be utilized for configuring the Effective Aperture AREAvariance described above.

As mentioned previously, the angle of orientation of the aperture canimpact the fluid handling capabilities of a crimped fiber spunbondnonwoven web or nonwoven laminate 2600. Moreover, length of theaperture, width of the aperture, Effective Aperture AREA, spacingbetween apertures, as well as aperture density can similarly impactfluid handling. However, length of apertures, width of apertures, angleof orientation, spacing and density can have competing/negative impactson the other variables. As stated previously, apertures which are at agreater angle to the machine direction 1675 tend to open less andtherefore have less Effective Aperture AREA than apertures which areeither parallel to the machine direction 1675 or which have a smallerangle with respect to the machine direction 1675. Similarly, angledapertures which are too closely spaced together tend to open less andtherefore have less Effective Aperture AREA. As such, spacing betweenadjacent angled apertures may be increased over that which is betweenapertures which are generally oriented parallel to the machine direction1675.

Additional aperture patterns are contemplated and are shown with regardto FIGS. 65-74.

Methods of Making Nonwoven Webs/Laminates Comprising Patterns ofApertures

The patterns of apertures of the present disclosure may be madegenerally by using the process generally described in U.S. Pat. No.5,628,097 entitled “Method for Selectively Aperturing a Nonwoven Web”which issued May 13, 1997 and U.S. Patent Publication 2003/0021951entitled “High Elongation Apertured Nonwoven Web and Method of Making”which published Jan. 20, 2003. Other methods of producing substratescomprising patterns of apertures known to those of skill in the art arealso within the scope of the present disclosure and include for examplerotary knife aperturing, hot pin aperturing, hydroentangling or needlepunching. Other suitable processes are disclosed in U.S. Pat. Nos.5,658,639; 5,628,097; 5,916,661; 7,917,985; and U.S. Patent ApplicationPublication No. 2003/0021951. Other suitable processes for formingapertures may include those described in U.S. Pat. Nos. 8,679,391 and8,158,043, and U.S. Patent Application Publication Nos. 2001/0024940 and2012/0282436. Still other suitable methods for aperturing webs areprovided in U.S. Pat. Nos. 3,566,726; 4,634,440; and 4,780,352.

Joining of Layers

The webs of a nonwoven laminate of the present invention or a nonwovenweb and adjacent layers in a disposable absorbent article may be bondedtogether using any bonding methods known to those of skill in the art,such as adhesive bonding, patterned adhesive coating, ultrasonicbonding, thermal bonding, mechanical bonding, or any combination ofthese bonding methods. Alternatively, the various layers may be bondedtogether only at the perimeter of the apertures, through bonding thelayers or overbonding the layers. The process of overbonding isdisclosed in U.S. Patent Application Ser. No. 62/076,043, entitled“Patterned Apertured Webs and Methods For Making the Same,” filed onNov. 6, 2014. Additional references include U.S. Pat. Nos. 5,658,639;5,628,097; 5,916,661; 6,498,284; 7,917,985; and U.S. Patent ApplicationPublication Nos. 2003/0021951; 2005/154362. Additional references forbonding nonwoven webs/laminates together include U.S. Pat. No. 7,056,404and U.S. application Ser. No. 14/135,687, filed on Dec. 20, 2013. And asnoted previously, in some forms of the present invention, the formationof overbonds may subsequently be processed into apertures. Additionaldisclosure regarding overbonds is provided hereafter.

The bonding may be done in a pattern of bonds or in arrays of bonds. Thepattern may be a regular, uniform pattern or an irregular, non-uniformpattern. The bonding patterns may comprise a substantially continuousbond pattern or may be formed of discrete bonding points. The discretebonding points may form a pattern. The pattern of bonding points may behomogeneous or non-homogeneous. A bond pattern in one region of anonwoven laminate of the present invention may differ from a bondpattern in another region of the nonwoven laminate. For example, thebond pattern may be different in the machine direction or thecross-machine direction of the nonwoven laminate. An absorbent articleincluding the nonwoven laminate may have a different bond pattern in thefront region vs. the back region, the center region vs. side regions, orthe crotch region vs. waist regions of the absorbent article, forexample. If adhesive is used in the bonding process, the adhesive may betinted, pigmented, and/or patterned to create a pattern as discussedhereafter. Bonding in nonwoven laminates is typically accomplished byjoining the land areas of various layers of the nonwoven laminates.

Substrates, layers, crimped fiber spunbond nonwoven webs and/or elementsof a nonwoven laminate and/or disposable absorbent articles may bebonded together by any suitable method. Some specific examples ofbonding can occur between multiple nonwoven layers of a topsheet. Inanother example, a topsheet (including one or more layers) may be bondedto a subjacent layer (layer between the topsheet and an absorbentcore)—including secondary topsheets, acquisition layers or the like. Inyet another example, the topsheet (including one or more layers) may bebonded to the absorbent core. In each of the above examples, theconstituent layers of the topsheet may be bonded together in a separatestep and then subsequently bonded to another component.

The bonding may comprise a pattern or a plurality of patterns which formgraphics and/or other depictions, hereafter “bond indicia”. Someexamples of bond indicia are shown in FIGS. 49-52. In another example,substrates, layers, crimped fiber spunbonded webs and/or elements of anonwoven laminate and/or disposable absorbent articles may be adhesivelybonded together. Any suitable method may be utilized to form fusionbonds between layers/substrates described herein. Some suitable examplesare ultrasonic, heated rolls, and the like.

Any suitable method may be utilized to form bonds betweenlayers/substrates described herein. Some suitable examples areultrasonic, heated rolls, and the like. In a specific example,substrates, layers and/or elements of a disposable absorbent articlesmay be bonded together via fusion bonding, ultrasonic bonding, or thelike. The bonding may comprise a pattern or a plurality of patternswhich form graphics and/or other depictions, hereafter “bond indicia”.In another example, substrates, layers and/or elements of disposableabsorbent articles may be adhesively bonded together.

The mechanical bonding methods, e.g. fusion bond, ultrasonic, etc. cancause localized areas of the web to thin and become film like—in thecase of nonwovens. These thinner areas can have different opacitycharacteristics with respect to the constituent material around thebond. As such, visual/color effects can be achieved. For example, thethinner areas may appear as a different color than the constituentmaterial around the bond.

Bonding of the layers of an absorbent article is critical to theperformance of said article. Bonding is important for the integrity ofthe product and of the layers to ensure sustained performance anddurability throughout wear. Bonding can ensure connectivity betweendesired layers of the product to aid in fluid transfer between thelayers. This is especially critical in nonwoven topsheet laminates witha hydrophobic nonwoven upper layer to ensure fluid access to thehydrophilic nonwoven lower layer. Fusion bonding has additionaladvantages over adhesive in that it lowers raw material cost, eliminatesline hygiene issues, and allows bonding of layers between which the useof adhesive would not be feasible.

In order to ensure the integrity of the product and of the crimped fiberspunbond nonwoven laminate topsheet, the total area of the bonding(calculated as a percent area of the outer perimeter of bonding region)may range from 5% to 25%, 10% to 20%, or 12% to 18%. The size of eachindividual fusion bond nub may range from 0.5 sqmm to 5 sqmm, 1 sqmm to3 sqmm. The spacing between fusion bond nubs can range from 1 mm to 5cm, 1.6 mm to 3 cm.

In some forms, the bonds, as stated previously, may be configured inpatterns so as to create bond indicia. But apart from forming bondindicia, the bonds can help secure the layers of the nonwoven laminatetogether. Additionally, in some forms, the bonds may be utilized tosecure the crimped fiber spunbond nonwoven web or nonwoven laminate toadjacent layers of a disposable absorbent article, e.g. a secondarytopsheet, absorbent core, etc.

As shown in FIGS. 49-52, bond patterns 3000A, 3000B, 3000C, and 3000D ofthe present invention may comprise a plurality of bond sites 3002. Thebond sites may be any suitable shape. As shown, the bond sites areapproximately circular; however, elliptical, diamond, heart, star,clover (3 leaf, 4 leaf), bowtie, combinations thereof, and the like arecontemplated. In some forms, the constituent bond sites 3002 of a fusionbond pattern may comprise combinations of shapes.

As shown, the fusion bond pattern 3000A may comprise a plurality ofarrays of bond sites, e.g. 3010, 3020, 3030, and 3040. The first array3010 may be a continuous series of bond sites 3002 which enclose thesecond array 3020, the third array 3030, and the fourth array 3040. Asshown, the second array 3020 may be discontinuous and disposed betweenthe first array 3010 and the third array 3030. The third array 3030,much like the first array 3010 may be continuous and may enclosed thefourth array 3040. The fourth array 3040 may be discontinuous and bedisposed in a target area on the absorbent article. The target areasignifies the location of the article which is likely to receive thefluid insult from the wearer assuming the absorbent product is donnedproperly.

With the discontinuous fourth array 3040, fluid insults can be providedwith adequate access to the nonwoven laminate. Additionally, with thecontinuous third array 3030, fluid insults are encouraged to stay withinthe target area as opposed to meandering to outer edges of the article.

As shown in FIG. 49, the fusion bond pattern 3000B may comprise aplurality of arrays of bond sites. For example, a first array 3010B maybe continuous and comprise bond sites which are arranged in the shape ofhearts, clouds, etc. A second array 3020B is disposed within the firstarray 3010B and disposed about a third array 3030B. The third array3030B is continuous and surrounds the fourth array 3040B. Much like thearrays of the fusion bond pattern 3000A, the arrays of the fusion bondpattern 3000B can provide fluid handling benefits.

As shown in FIG. 50, a fusion bond pattern 3000C may comprise aplurality of arrays of bond sites. However, in contrast with theprevious fusion bond patterns, a first array 3010C may be discontinuousabout the entire periphery of a pad. As shown, the first array 3010Ccomprises a plurality of continuous segments of bond sites each of whichis disconnected from one another. A second array 3020C may be disposedinboard of the first plurality 3010C and may also comprise a pluralityof continuous segments which are discontinuous. A third array 3030C maycomprise continuous bond sites and enclose a fourth array 3040C. Thefourth array 3040C comprises a plurality of discontinuous bond sites.Much like the fusion bond patterns discussed previously, the fusion bondpattern 3000C may provide fluid handling benefits.

As shown in FIG. 51, a fusion bond pattern 3000D may comprise aplurality of arrays of bond sites. For example, a first array 3010D maycomprise a plurality of bond sites which are arranged in a continuousfashion and may enclosed a second array 3020D, a third array 3030D and afourth array 3040D of bond sites. The second array 3020D may comprise aplurality of bond sites which form continuous elements as well as aplurality of bond sites which form discontinuous elements. Thesecontinuous elements may be disposed at a first end and second end of theabsorbent article. The third array 3030D of plurality of bond sites maybe continuous and may enclosed the fourth array 3040D. The fourth array3040D may comprise a plurality of bond sites which form a plurality ofelements. Each of the elements may be continuous but discontinuous withrespect to the other elements. For example, each element may comprise aplurality of bond sites, e.g. 4. The bond sites would be consideredcontinuous for each respective element, but the bond sites from elementto element would be discontinuous.

Patterned Adhesive

As noted previously, the nonwoven laminates of the present inventioncomprise at least two webs and may include additional webs—at least oneof the webs being a crimped fiber spunbond nonwoven. In some forms,adhesive may be used to join the layers of the nonwoven laminatetogether and/or may be utilized to join the nonwoven laminate to aportion of an absorbent article. In some forms, adhesive may be used tojoin a crimped fiber spunbond nonwoven web to adjacent layers/elementsof a disposable absorbent article. The adhesive may comprise a pigment,a tint, or a dye. The colored adhesive, in a form, may be positionedbetween the first layer and second layer of a nonwoven laminate. In someforms, more than one colored adhesive may be used in a nonwovenlaminate. The colored adhesive may also be situated in any suitablelocation when joining two or more webs (e.g., on the surface of orintermediate any of the layers). The colored adhesive may also bedeposited in zones and/or in patterns throughout the joined layers. Thecolored adhesive may be different or the same in different zones of thejoined layers. The colored adhesive may be positioned intermediate thelayers of the joined layers or positioned on any other surfaces of thejoined layers. Additional layers may also be provided having one or morecolored adhesives. As stated previously, adhesive and particularlycolored adhesive may be applied such that the adhesive forms a patternor a plurality of patterns which form graphics and/or other depictions,referred to as “adhesive indicia.” Adhesive indicia, in some forms, mayalso be created via the use of clear adhesive. The application of clearadhesive, in some instances can change the opacity of materials whichare being adhesively joined.

In an instance, a colored adhesive may be positioned between two lowbasis weight materials (e.g., 15 gsm or less, 10 gsm or less) forming anonwoven laminate, so that the colored adhesive may be visible fromeither side of the nonwoven laminate. In a topsheet context, this canprovide a high basis weight topsheet to achieve improved softness, whilestill retaining the benefit of seeing the colored adhesive from eitherside of the nonwoven laminate.

As stated previously, the adhesive utilized to bond/join layers and/orelements of disposable absorbent articles using the crimped fiberspunbond nonwoven webs/nonwoven laminates of the present invention maycomprise adhesive indicia. Accordingly, the nonwoven laminates and/orabsorbent articles of the present disclosure, or portions thereof, maycomprise one or more patterned adhesives applied thereto or printedthereon. The patterned adhesives may be associated with the crimpedfiber spunbond nonwoven webs/nonwoven laminates such that at least aportion of the patterned adhesives can be viewable through the crimpedfiber spunbond nonwoven web/nonwoven laminates, e.g. through aperturesand/or land areas. Patterned adhesives are adhesives that are applied toone or more layers, or between layers, in particular patterns to providethe absorbent articles, or portions thereof, with certain patterns,visible patterns, and/or certain textures. The patterned adhesives maybe printed on or otherwise applied to any suitable layer of theabsorbent articles. Methods for applying patterned adhesives to layersor substrates by adhesive printing are disclosed, for example, in U.S.Pat. No. 8,186,296, to Brown et al., issued on May 29, 2012, and in U.S.Pat. Appl. Publ. No., 2014/0148774, published on May 29, 2014, to Brownet al. Other methods of applying patterned adhesives to substrates knownto those of skill in the art are also within the scope of the presentdisclosure.

A patterned adhesive may have the same color or a different color as atleast one layer of a nonwoven laminate or different than a color of thecrimped fiber spunbond nonwoven web. In some instances, the patternedadhesive may have the same or a different color as both or all layers ofa nonwoven laminate. In some instances, aperture patterns in at leastone layer of a crimped fiber spunbond nonwoven webs/nonwoven laminatemay coordinate with patterned adhesive to visually create athree-dimensional appearance. The apertured patterns may be the same ordifferent than patterns of the patterned adhesive.

In an instance, a nonwoven laminate may comprise a first layercomprising a plurality of apertures and a plurality of land areas and asecond layer comprising a plurality of apertures and a plurality of landareas. A patterned pigmented substance, such as ink or a patternedadhesive, may be positioned at least partially intermediate the firstlayer and the second layer. The plurality of apertures of the firstlayer may be at least partially aligned with the plurality of aperturesof the second layer. The patterned pigmented or colored substance may beat least partially viewable through the aligned portions of theapertures in the first and second layers. Examples of patterned adhesiveare provided with regard to FIGS. 75-81.

Regarding FIGS. 75-77, a plurality of overbonds are shown on a webarranged in a plurality of arrays which will eventually—when processedas described herein—produce apertured indicia. In FIG. 76 adhesiveindicia on a web is depicted. As noted previously, the adhesive maycomprise a color or may be clear in some forms. Regarding FIG. 77, acombination of the overbonds of FIG. 75 and the adhesive indicia of FIG.76 are shown. Note that given the arrangement of the overbonds of FIG.75, the resulting apertured indicia would appear similar (coordinated)with the adhesive indicia shown in FIG. 76. In such forms, it may bebeneficial to register the apertured indicia with the adhesive indiciato produce the desired visual effect. Adhesive indicia and aperturedindicia which may not require registration are depicted in FIGS. 78-80.A similar effect is depicted in FIG. 81.

Regarding FIG. 81, a combination of apertured indicia and adhesiveindicia is shown on a web. The apertured indicia and the adhesiveindicia are not registered. As such, portions of the adhesive indiciaare visible through only a portion of the apertures. The effect canhighlight portions of the adhesive indicia which are visible through theapertures. The remainder of the adhesive indicia may still be visiblethrough the web which comprises the apertured indicia.

Printing

Either in addition to or in lieu of the various layers/web beingcolored, one or more of the layers of the nonwoven laminates or thecrimped fiber spunbond nonwoven webs of the present disclosure mayinclude printing, e.g., with ink or a pigmented or colored pattern. Theink may be deposited via any printing process known in the artincluding, but not limited to, flexographic printing and digital inkjetprinting. The printing may comprise a pattern or a plurality of patternswhich form graphics and/or other depictions, hereafter, “printedindicia.” The printing may be on an external surface of a first layer ofthe nonwoven laminate, between the first and second layers of thenonwoven laminate, or may be on a surface beneath the second layer ofthe nonwoven laminate. The printing may also be situated in any suitablelocation if the nonwoven laminate has more than two layers (e.g., on thesurface of any of the layers). The printing may also be deposited inzones of the nonwoven laminate and/or in patterns throughout thenonwoven laminate. The printing may be different or the same indifferent zones of the nonwoven laminate. If the printing will becovered by one of the layers, e.g. the covering layer, it may have arelatively low opacity to enhance the visual appearance of the printing.The density of the printing (e.g., clarity and contrast) may be enhancedby including small-denier fibers in the printed layer including, but notlimited to, melt-blown fibers, microfibers, and nanofibers. The printingmay be on the first layer, the second layer, and/or may be on a separatelayer positioned at least partially intermediate the first and secondlayers. In an instance, the printing may indicate the proper orientationof an absorbent article on a wearer (e.g., front/rear). It will beunderstood that printing may be used with any of the various forms andconfigurations of the nonwoven laminates disclosed herein. In someforms, more than one type or color, for example, of printing may be usedin a single nonwoven web. Additional layers may also be provided in anonwoven laminate having one or more printed patterns.

Coordinated Patterns

Heretofore, bond indicia, adhesive indicia, structural indicia, andprinted indicia have been introduced. Additionally, for those formswhere the crimped fiber spunbond nonwoven webs and/or nonwoven laminatesof the present invention comprise patterned apertures, the array ofapertures may comprise a pattern or a plurality of patterns which formgraphics and/or other depictions, hereafter, “apertured indicia.” Theapertured indicia may coordinate with at least one of printed indicia,bond indicia, adhesive indicia, and/or structural indicia. For example,in the absorbent article context, located beneath the nonwoven laminateor within the nonwoven laminate adhesive indicia may be present whichcoordinate with the apertured indicia. In an instance, the nonwovenlaminate may be used a topsheet, an outer cover, an ear, or otherportion of an absorbent article.

The aperture pattern in a nonwoven web may coordinate with featuresunder it, such as bond sites, material edges, channels, and/ordiscolored or colored materials. In some specific executions, thenonwoven web may be used to accentuate or block/hide these features. Theaperture patterns of a nonwoven laminate may also be used to indicatethe correct front vs. rear, left vs. right orientation of an absorbentarticle or other consumer product.

Apertured indicia may be coordinated with printed indicia elsewhere onthe product and/or packaging. For example, a disposable absorbentarticle of the present invention may comprise apertured indicia whichprovides the appearance of a snowflake. The article may additionallycomprise printed indicia elsewhere on the article itself and/or itspackaging, wherein the printed indicia provides the appearance of asnowflake. In such embodiments, the feminine article may comprise arelease liner which includes a printed snowflake pattern and/or beplaced in a package comprising a printed snowflake pattern.

Forms of the present invention are contemplated where the aperturedindicia is coordinated with adhesive indicia, bond indicia, and/orstructural indicia. Embodiments are contemplated where at least two ofthe following are coordinated on an absorbent article: aperturedindicia, adhesive indicia, printed indicia, bond indicia, structuralindicia. Similar embodiments are contemplated with regard to thepackaging for the disposable absorbent articles described herein(including release liners and/or secondary packaging). Additionally, theaforementioned indicia may be coordinated across the absorbent article,its packaging, and/or its secondary packaging (including release liners)or any combination thereof.

In some specific forms, while a portion of the topsheet may includeapertured indicia, other portions of the topsheet may include printedindicia which is coordinated with the apertured indicia. In other forms,a sub-layer, e.g. acquisition layer, secondary topsheet, and/orabsorbent core may comprise printed indicia which is coordinated withthe apertured indicia of the topsheet. Still in other forms, thebacksheet may comprise printed indicia which is coordinated with theapertured indicia of the topsheet. Additional forms are contemplatedwhere a portion of the topsheet includes apertured indicia, thebacksheet includes printed indicia coordinated with the aperturedindicia, packaging of the feminine article includes printed indiciacoordinated with the apertured indicia, a non-apertured portion of thetopsheet includes printed indicia which is coordinated with theapertured indicia and/or a sub-layer, e.g. acquisition layer, secondarytopsheet, and/or absorbent core comprise printed indicia which iscoordinated with the apertured indicia. Similar embodiments arecontemplated with adhesive indicia, structural indicia, bond indicia,and/or any combinations thereof.

In other specific forms, the topsheet may comprise apertured indicia andfirst printed indicia. The first printed indicia may coordinate withsecond printed indicia on secondary packaging while apertured indiciamay coordinate with printed indicia on primary packaging for theabsorbent article.

Indicia is visually coordinated when one or more elements of the indiciahave two or more visual characteristics that are either matched or arecaused to match. As used herein, the term “match” or “matched” is usedto describe the way or degree to which apertured indicia, printedindicia, bond indicia, adhesive indicia, and/or structural indicia, orcharacteristics thereof visually fit together or are caused to fittogether. For example, apertured indicia and printed indicia areconsidered matched if some aspects of the apertured indicia areidentical to similar aspects of the printed indicia. In one form ofmatch, for example, apertured indicia and printed indicia that resembleeach other are said to match. The same can be true for any combinationof the heretofore mentioned indicia. As used herein, the term“coordinate” or “coordination” is used to describe how indicia of theoverall absorbent article and/or its packaging visually belong together.Components or elements are considered to be coordinated if they match,or are caused to match. As used herein, the term “caused to match” isused to describe how any combination of aforementioned indicia are madeto appear matched to one another by using coordinating indicia (anycombination of the above) which has a coordinating feature which tiesthe aforementioned indicia together. For example, if apertured indiciaand printed indicia each have a visual characteristic different from oneanother and coordinating indicia has visual characteristics which matcheach of the apertured indicia and printed indicia, the coordinatingfeature causes the apertured indicia and printed indicia to be matchedto one another.

Additionally, patterns comprising multiple features may be coordinated.As an example, a first array of apertures may be grouped with adjacentbond sites to form a pattern unit. This pattern unit may be repeating.For example, a first pattern unit may be disposed adjacent a first endof an absorbent article while a second pattern unit is disposed adjacenta second end of an absorbent article. As another example, the firstpattern unit may be disposed adjacent a first end of an absorbentarticle while the second pattern unit is disposed adjacent a transverseaxis of the absorbent article. Still another example may compriseadditional pattern units which may be disposed in any suitable locationon an absorbent article. Pattern units may comprise any combination offeatures. For example a pattern unit may comprise apertures, bonds,print, structures, or combinations thereof.

Some examples of coordinated indicia include theme related indicia. Insome embodiments, indicia described herein may be coordinated where atleast two of the indicia, e.g. apertured and printed include at leastone of items generally thought of as lucky, e.g. balloons, rainbows,pots of gold, moons (printed indicia may include blue moon), clovers,horseshoes, stars, hearts, and the like or combinations thereof. Otherexamples of coordinated indicia include numbers, letters, combinationsof numbers and letters; winter themes including snowflakes and/or thelike; spring themes including flowers, bees, birds, trees, sun,geometric shapes, squares, rectangles, triangles, oval, circles; curvesincluding uni-radial arcs, multi-radial arcs, spirals, truncatedsinusoidal waves.

Crimped fiber spunbond nonwoven webs/nonwoven laminates of the presentinvention may be utilized in multiple areas of the disposable absorbentarticles described herein. For example, in some embodiments, a nonwovenlaminate of the present invention may be utilized as a leg cuff of anabsorbent article, a backsheet and/or outer cover, and/or a topsheet.For such embodiments, the array of apertures utilized for the topsheetmay be coordinated with the array of apertures utilized for the legcuffs and/or backsheet. In some embodiments, the array of apertures inthe leg cuff may coordinate with the array of apertures for thebacksheet but not for the topsheet. In other embodiments, the array ofapertures of the backsheet may coordinate with the array of aperturesfor the topsheet.

If a crimped fiber spunbond nonwoven web/nonwoven laminate is used aspart, or all of, an outer cover (garment-facing layer) of an absorbentarticle, the aperture pattern or patterns may provide enhancedbreathability in certain regions (e.g., waist, hips) or reducedbreathability in areas over an absorbent core, for example. The aperturepattern or patterns in a nonwoven laminate used as an outer cover mayalso provide enhanced textures and/or signals in certain regions of theouter cover. Such texture and/or signals may provide intuitiveinstructions on how to property apply the absorbent article, where togrip the absorbent article, and/or where/how to fasten the absorbentarticle, among other functions, such as to enhance graphics oraesthetics.

If a crimped fiber spunbond nonwoven web/nonwoven laminate is used as aportion of a fastener (e.g., taped fastener) of an absorbent article, anapertured pattern of a crimped fiber spunbond nonwoven web/nonwovenlaminate of the fastener may indicate how to grip and fasten thefastener and indicate when it is and is not fastened correctly. Anapertured pattern of the crimped fiber spunbond nonwoven web/nonwovenlaminate used as a fastener, or portion thereof, may coordinate with anaperture pattern of a crimped fiber spunbond nonwoven web/nonwovenlaminate used as a topsheet and/or an outer cover of the same absorbentarticle to signal a holistic function.

In another form, crimped fiber spunbond nonwoven web/nonwoven laminatesof the present invention may comprise a nonwoven layer (comprisingspunbond crimped fiber) and a film. The laminate can be joined togethervia glue lamination or extrusion lamination—film extruded onto thecrimped fiber spunbonded nonwoven web. Such laminates may be utilized asa topsheet and/or a backsheet of an absorbent article. Regarding suchlaminates—in the context of topsheets—the film may serve as an upperlayer while the crimped fiber spunbond nonwoven layer may serve as thelower layer (more proximal to the absorbent core than the upper layer)of the laminate. In the context of backsheets, the film may form a lowerlayer of the laminate while the crimped fiber spunbond nonwoven webforms the upper layer (more outer facing than the lower layer) of theabsorbent article. The optimum balance of bodily exudate acquisitionspeed and rewet in an absorbent article comprising a nonwoven laminateas a topsheet and/or topsheet and acquisition system may be derived froma combination of aperture diameter, shape or area, depth or thickness ofthe nonwoven laminate, and the spacing between the various apertures oraperture arrays within the nonwoven laminate.

An absorbent article comprising a nonwoven laminate as a topsheet and/ora topsheet and an acquisition system may comprise a longitudinal axis,much like the longitudinal axis of 1880 of FIG. 26. Arrays of aperturesin the nonwoven laminate may repeat themselves along a line that isangled about 20 degrees to about 160 degrees from a longitudinal axis,e.g. 1880 which is generally parallel to the MD direction 1675 (shown inFIG. 34), specifically reciting all 1 degree increments within thespecified range and all ranges formed therein, relative to thelongitudinal axis. Additionally, there may be a plurality of aperturesizes, shapes, or areas along the line or the spacing between theapertures may not the same between all of the apertures along the linefor purposes of channeling liquid bodily exudates into preferred areasof the absorbent article or the absorbent core thereof to help avoidleakage.

An aperture pattern in a nonwoven laminate may form a recognizablevisual element, such as a heart or a water droplet, for example. Anaperture pattern that forms one or more water droplet shapes in anonwoven laminate used as a topsheet or an outer cover of an absorbentarticle may be used to aid communication of absorbency and/or wetness.Such a feature may be combined with a wetness indicator of an absorbentarticle.

Various commonly understood shapes may be created in a crimped fiberspunbond nonwoven web/nonwoven laminate. These shapes may be shapes thathave commonly understood proper orientations, such as hearts, forexample. An example is the use of one or more hearts on an outer coveror topsheet of a front waist region and/or a back waist region of adiaper. The caregiver would understand to place the diaper on the wearerwith the point of the heart facing toward the wearer's feet or towardthe posterior portion of a wearer's body because of the common knowledgeof the orientation of hearts.

In one instance, a nonwoven laminate of the present invention maycomprise a first non-apertured layer comprising a pattern having a colorand a second layer comprising a pattern of apertures. The pattern on thefirst non-apertured layer may be printed on the layer, for example, andmay form graphics or other indicia. At least 50% to 100% of the patternon the first non-apertured layer may be aligned with the pattern ofapertures to draw attention to the apertures. The alignment, or partialalignment, of the pattern of apertures on the first layer with thepattern having a color of the second layer may make aid in aligning theproduct on a wearer if the nonwoven laminate is provided on an absorbentarticle. In other examples, a nonwoven laminate may comprise a firstlayer and a second layer which are co-apertured as described herein. Insuch configurations, the first layer may be fused to the second layerabout a periphery of each of the apertures formed in the nonwovenlaminate. In such configurations, the first layer may have a differentcolor than the second layer. In yet another example, a first layer maybe apertured and may be joined to a second layer which is not apertured.In such configurations, the first layer and the second layer maycomprise different colors. In another example, a crimped fiber spunbondnonwoven web may comprise apertures while a subjacent layer in anabsorbent article comprises printed indicia and/or adhesive indicia. Theprinted indicia and/or adhesive indicia may be at least partiallyaligned with the apertures of the crimped fiber spunbond nonwoven web.

Additional forms are contemplated where the first layer of a nonwovenlaminate comprises a first color and the second layer of the nonwovenlaminate comprises a second color. The first color and the second colormay be different. In a specific form where the nonwoven laminate isutilized as a topsheet, subjacent layers to the topsheet, e.g. disposedbetween the topsheet and the absorbent core can have a third color. Thethird color may be different than the first and the second colors. Forother forms, a nonwoven laminate comprises a first layer and a secondlayer comprising a first color and second color, respectively, which aredifferent from one another. Additionally, where the nonwoven laminate isutilized as a topsheet, a secondary topsheet—disposed between thetopsheet and an absorbent core—may comprise printing/printed indicia.Such printing may be of a different color than that of the first colorand/or the second color. And, such printing is visible through thetopsheet such that the wearer can view the printing prior to donning theabsorbent article. Where a crimped fiber spunbond nonwoven web isutilized, subjacent layers of an absorbent article may be configuredsimilarly.

The apertured indicia, printed indicia, adhesive indicia, bond indiciawhen used on a topsheet and/or backsheet of a disposable absorbentarticle, may be utilized to ensure proper alignment of the absorbentarticle. For example, any one of apertured indicia, printed indicia,adhesive indicia, bond indicia, and/or combinations thereof, may beutilized to highlight proper alignment. In one specific example, printedindicia may be utilized to communicate to a wearer the properorientation of a feminine hygiene pad. Proper orientation of thefeminine hygiene pad can reduce the likelihood of leakage.

Additionally, the apertured indicia, printed indicia, adhesive indicia,bond indicia when used on a topsheet and/or backsheet of a disposableabsorbent article may be utilized to highlight features of the absorbentarticle which would otherwise not be noticeable by simple visualinspection of the article. For example, absorbent cores of disposableabsorbent articles are generally disposed between the topsheet and thebacksheet. In many instances, upon visual inspection, a wearer may notbe able to discern the boundaries of the absorbent core which aretypically inboard of the periphery of the absorbent article. In suchinstances, at least one of apertured indicia, printed indicia, adhesiveindicia, bond indicia or any combination thereof, may be utilized tocommunicate the boundaries of the absorbent core. This may provide somereassurance to the wearer regarding the “zone” of absorbency. Still inother configurations, at least one of apertured indicia, printedindicia, adhesive indicia, bond indicia or any combination thereof, maybe utilized to communicate a particular area of the absorbent core. Forexample, an absorbent article may comprise an absorbent core havingvariable absorbing capacity. In such instances, at least one of theapertured indicia, printed indicia, adhesive indicia, bond indicia orany combination thereof, may be utilized to highlight an area of thecore having higher absorbing capacity than other areas. Conversely,apertured indicia, printed indicia, adhesive indicia, bond indicia orany combination thereof, may be utilized to highlight those portions ofthe absorbent core which have lower capacity than another portion of theabsorbent core. Still other executions are contemplated where a firstarray of apertured indicia, printed indicia, adhesive indicia, bondindicia or any combination thereof is utilized to communicate to thewearer a portion of the absorbent core having higher absorbing capacitythan other portions while a second array of apertured indicia, printedindicia, adhesive indicia, bond indicia or any combination thereof areused to communicate to the wearer regarding other portions of theabsorbent core having lower absorbing capacity. In such executions, thefirst array and the second array may or may not be coordinated.

Zones

In any context of a crimped fiber spunbond nonwoven web/nonwovenlaminate, but especially in an absorbent article context, the crimpedfiber spunbond nonwoven web/nonwoven laminates may be employed in azonal fashion. For instance, a first zone of a topsheet of an absorbentarticle may have a first aperture pattern, while a second zone of atopsheet of an absorbent article may have a second, different aperturepattern.

Aperture patterns in the different zones may be configured to receivecertain bodily exudates or inhibit or encourage their flow in anydesired direction. For example, the first pattern may be betterconfigured to receive and/or direct the flow of urine, while the secondpattern may be better configured to receive and/or direct the flow ofrunny BM. In other instances, a first zone having a first pattern may beconfigured to receive heavy gushes of bodily exudates while a secondzone having a second different pattern may be configured to restrictlateral bodily exudate flow in any desired direction. The first patternmay be situated in, for instance, the middle of the absorbent article orin the crotch region, while the second pattern may be situated in thefront and rear waist regions or outer perimeter topsheet regions of theabsorbent article.

The zones in a crimped fiber spunbond nonwoven web/nonwoven laminate maybe positioned in the machine direction, the cross direction, or may beconcentric. If a product, such as an absorbent article, has twodifferent zones in the machine direction, the zones may have the same ora similar cross-direction width (e.g., +/−2 mm) for ease in processing.One or more of the zones may have curved or straight boundaries orpartial boundaries.

Any suitable zones, including more than two, of different or the samecrimped fiber spunbond nonwoven web/nonwoven laminates are envisionedwithin the scope of the present disclosure. The various zones may be inthe topsheet as mentioned above, but may also be present on an outercover or a cuff for example. In some instances, the same or a differentpattern of zones of crimped fiber spunbond nonwoven web/nonwovenlaminates may be used on the wearer-facing surface (e.g., topsheet) andthe garment-facing surface (e.g., outer cover).

In an instance, a topsheet or other portion of an absorbent article mayhave two or more zones in a crimped fiber spunbond nonwoven web/nonwovenlaminate. For example, a first zone of the nonwoven laminate may have adifferent aperture pattern than a second zone. The first zone and thesecond zone may have different functionalities owing to the differentaperture patterns. A functionality of the first zone may be to provideliquid bodily exudate distribution (fluid moving on the nonwovenlaminate), while the functionality of the second zone may be to provideliquid bodily exudate acquisition (fluid penetrating the nonwovenlaminate). Benefits of such a zoned crimped fiber spunbond nonwovenweb/nonwoven laminate can be better use of an absorbent core and moreefficient liquid bodily exudate distribution within the absorbent core.This is especially important if an air-felt free core is used in thattypical air-felt free cores somewhat struggle with liquid bodily exudatedistribution once the liquid bodily exudate is received therein.

In an example, an absorbent article may comprise a nonwoven laminatethat forms a first portion and a second, different portion thereof.Aperture patterns in each portion of the nonwoven laminate may be thesame, substantially similar, or different. In another instance, anabsorbent article may comprise a nonwoven laminate that comprises afirst portion of an absorbent article, and wherein a second portion ofthe absorbent article has graphics, printing, patterned adhesives, orother indicia that forms a pattern that is similar to, substantiallysimilar to, coordinates with, or is different than an aperture patternin the nonwoven laminate. Crimped fiber spunbond nonwoven webs of thepresent invention may be similarly configured.

In some forms, a crimped fiber spunbond nonwoven web/nonwoven laminatemay have a plurality of zones. A first zone may have at least someapertures having a first feret angle, first size, and/or first shape,while a second zone (or third or fourth zone etc.) may have apertureshaving a second, different feret angle, second, different size, and/orsecond, different shape.

As stated previously, the crimped fiber spunbond nonwoven web/nonwovenlaminates of the present invention may be utilized in a number ofdifferent components of absorbent articles. Referring to FIG. 53, in onespecific example, disposable absorbent articles utilizing the crimpedfiber spunbond nonwoven web/nonwoven laminate of the present inventionmay comprise a plurality of zones. As shown, a topsheet 2014 of adisposable absorbent article 2010, may comprise a first zone 2007, asecond zone 2011 and a third zone 2013. Absorbent articles may comprisemore zones or less zones as described hereafter.

The first zone 2007 may comprise an array of apertures as describedherein. As shown the first zone 2007 may have a width parallel to alateral axis 2090 which does not extend the full width of the topsheet2014. Instead, the second zone 2011 and the third zone 2013 may beplaced on either side of the first zone 2007. In some embodiments, thesecond zone 2011 and the third zone 2013 may comprise a first array ofstructures and a second array of structures, respectively. For theseforms, the array of apertures in the first zone 2007 may form aperturedindicia which may be coordinated with the array of structures in thesecond zone 2011 and/or the array of structures in the third zone 2013.In a specific execution, the first zone 2007 comprises an array ofapertures, the second and third zones 2011 and 2013, respectively,comprise an array of structures, wherein the array of structures in boththe second zone 2011 and the third zone 2013 comprise tufts 1770oriented in the Z-direction or negative Z-direction.

Still in other embodiments, the first zone 2007 may comprise an array ofout-of-plane deformations while the second zone 2011 and the third zone2013 comprise a first array of apertures and a second array ofapertures, respectively. In such forms, the array of out-of-planedeformations may be coordinated with the array of apertures in thesecond zone 2011 and the third zone 2013.

In some embodiments, the first zone 2007 may comprise the array ofapertures as well as an array of bonds. The bonds, as mentionedpreviously, may be configured to provide bond indicia. In someembodiments, bond indicia may be coordinated with the apertured indiciain the first zone 2007. In other embodiments, bond indicia may bepresent, in addition to the first zone 2007, in the second zone 2011and/or third zone 2013. In such embodiments, the bond indicia may becoordinated with the apertured indicia in the first zone 2007 or may beun-coordinated with respect to the apertured indicia. Adhesive indicia,printed indicia may similarly be provided in the first zone 2007, thesecond zone 2011, and/or the third zone 2013. In such embodiments, theadhesive indicia, printed indicia may be coordinated with the aperturedindicia or may be un-coordinated with the apertured indicia. In aspecific execution, the first zone 2007 comprises an array of aperturesforming apertured indicia and an array of fusion bonds forming bondindicia. The second zone 2011 and the third zone 2013 may each comprisean array of structures, wherein the array of structures comprise tufts1770 oriented in the Z-direction. In such executions, the aperturedindicia may be coordinated with bond indicia. In other executions, bondindicia may not be coordinated with apertured indicia.

In some forms, the first zone 2007, the second zone 2011 and/or thethird zone 2013 may comprise a plurality of indicia selected fromprinted indicia, apertured indicia, adhesive indicia, structuralindicia, and bond indicia. In such forms, any combination of theplurality of indicia may be coordinated with indicia within itsrespective zone and/or with regard to one of the other or both zones.

While heretofore, zones have been disclosed primarily in the context ofnonwoven laminates, nonwoven laminates without apertures, nonwovenlaminates without patterned apertures, and crimped fiber spunbondnonwoven webs of the present invention may similarly comprise variablezones. For example, the first zone 2007 may comprise printed indiciawhile the second zone 2011 and the third zone 2013 comprise structuralindicia. The printed indicia and the structural indicia may becoordinated. In other examples, the first zone 2007 may compriseadhesive indicia while the second and the third zones 2011 and 2013,respectively, comprise structural indicia. The adhesive indicia may becoordinated with the structural indicia. In yet another example, thefirst zone 2007 may comprise bond indicia while the second zone 2011 andthird zone 2013 comprise structural indicia. The bond indicia may becoordinated with the structural indicia. Still in other forms, the firstzone 2007 may comprise apertured indicia and printed indicia while thesecond zone 2011 and the third zone 2013 comprise structural indicia.The structural indicia may be coordinate with the apertured indiciawhich in turn may be coordinated with the printed indicia.

Suitable configurations of zones are described with regard to FIGS.54-57. FIGS. 54-57 may represent a portion of a wearer-facing surface ofan absorbent article, such as a diaper, an adult incontinence product,and/or a sanitary napkin.

FIG. 54 illustrates an example of a substrate having three zones. Thefront portion, F, may be positioned in a front portion of an absorbentarticle or a back portion of an absorbent article. The back portion, B,may be positioned in a front portion of an absorbent article or a backportion of an absorbent article. A first zone 4004 and a second zone4006 may be positioned intermediate two portions of the third zone 4008.The zones 4004, 4006, and 4008 may be provided as separate pieces ofmaterial that are partially overlapped and joined or bonded together ormay be provided as one piece of material. In an instance, the first zone4004 and the second zone 4006 may be provided as one piece of materialor as two pieces of material that partially overlapped and joined orbonded together.

The first zone 4004 may comprise a plurality of out-of-planedeformations as described above with reference to FIGS. 2A-9B. Theout-of-plane deformations may extend upwardly out of the page ordownwardly into the page. The second zone 4006 may comprise a pluralityof out-of-plane deformations as described above with reference to FIGS.2A-9B. The out-of-plane deformations may extend upwardly out of the pageor downwardly into the page. The second zone 4006 may have a differentor the same pattern, shape, size, and/or orientation of the out-of-planedeformations compared to the pattern, shape, size, and/or orientation ofthe first zone 4004. The third zone 4008 may comprise a pattern ofapertures, wherein at least two apertures of the pattern of apertureshave different sizes, shapes, and/or orientations. The pattern ofapertures may be any of the various patterns described herein or othersuitable patterns. A substantially-laterally extending separationelement, 4010, may extend between the intersection of the first zone4004 and the second zone 4006.

In another instance, still referring to FIG. 54, the first zone 4004 maycomprise a pattern of apertures, wherein at least two apertures of thepattern of apertures have different sizes, shapes, and/or orientations.The pattern of apertures may be any of the various patterns describedherein or other suitable patterns. The second zone 4006 may comprise apattern of apertures, wherein at least two apertures of the pattern ofapertures have different sizes, shapes, and/or orientations. The patternof apertures may be any of the various patterns described herein orother suitable patterns. The second zone 4006 may have a different orthe same pattern of apertures as the first zone 4004. The third zone4008 may comprise a plurality of out-of-plane deformations as describedabove with reference to FIGS. 2A-9B. The out-of-plane deformations mayextend upwardly out of the page or downwardly into the page. Asubstantially-laterally extending separation element, 4010, may extendbetween the intersection of the first zone 4004 and the second zone4006.

FIG. 55 illustrates an example of a substrate having a first zone 4012and a second zone 4014. The front portion, F, may be positioned in afront portion of an absorbent article or a back portion of an absorbentarticle. The back portion, B, may be positioned in a front portion of anabsorbent article or a back portion of an absorbent article. The zones4012 and 4014 may be provided as two separate pieces of material thatare partially overlapped and joined or bonded together or may beprovided as one piece of material. The first zone 4012 may comprise apattern of apertures, wherein at least two apertures of the pattern ofapertures have different sizes, shapes, and/or orientations. The patternof apertures may be any of the various patterns described herein orother suitable patterns. The second zone 4014 may comprise a pluralityof out-of-plane deformations as described above with reference to FIGS.2A-9B. The out-of-plane deformations may extend upwardly out of the pageor downwardly into the page. A substantially-laterally extendingseparation element, 4010, may extend between the intersection of thefirst zone 4012 and the second zone 4014.

In another instance, still referring to FIG. 55, the second zone 4014may comprise a pattern of apertures, wherein at least two apertures ofthe pattern of apertures have different sizes, shapes, and/ororientations. The pattern of apertures may be any of the variouspatterns described herein or other suitable patterns. The first zone4012 may comprise a plurality of out-of-plane deformations as describedabove with reference to FIGS. 2A-9B. The out-of-plane deformations mayextend upwardly out of the page or downwardly into the page. Asubstantially-laterally extending separation element, 4010, may extendbetween the intersection of the first zone 4012 and the second zone4014.

FIG. 56 illustrates an example of a substrate having a first zone 4016and a second zone 4018. The front portion, F, may be positioned in afront portion of an absorbent article or a back portion of an absorbentarticle. The back portion, B, may be positioned in a front portion of anabsorbent article or a back portion of an absorbent article. The zones4016 and 4018 may be provided as two separate pieces of material thatare partially overlapped and joined or bonded together or may beprovided as one piece of material. The second zone 4018 may at leastpartially, or fully, surround the first zone 4016.

Still referring to FIG. 56, the first zone 4016 may comprise a pluralityof out-of-plane deformations as described above with reference to FIGS.2A-9B. The out-of-plane deformations may extend upwardly out of the pageor downwardly into the page. The second zone 4018 may comprise aplurality of out-of-plane deformations as described above with referenceto FIGS. 2A-9B. The out-of-plane deformations may extend upwardly out ofthe page or downwardly into the page. The second zone 4018 may have adifferent or the same pattern, shape, size, and/or orientation of theout-of-plane deformations compared to the pattern, shape, size, and/ororientation of the first zone 4016.

In another instance, still referring to FIG. 56, the first zone 4016 maycomprise a pattern of apertures, wherein at least two apertures of thepattern of apertures have different sizes, shapes, and/or orientations.The pattern of apertures may be any of the various patterns describedherein or other suitable patterns. The second zone 4018 may comprise aplurality of out-of-plane deformations as described above with referenceto FIGS. 2A-9B. The out-of-plane deformations may extend upwardly out ofthe page or downwardly into the page.

In yet another instance, still referring to FIG. 56, the second zone4018 may comprise a pattern of apertures, wherein at least two aperturesof the pattern of apertures have different sizes, shapes, and/ororientations. The pattern of apertures may be any of the variouspatterns described herein or other suitable patterns. The first zone4016 may comprise a plurality of out-of-plane deformations as describedabove with reference to FIGS. 2A-9B. The out-of-plane deformations mayextend upwardly out of the page or downwardly into the page.

In another instance, still referring to FIG. 56, the first zone 4016 maycomprise a pattern of apertures, wherein at least two apertures of thepattern of apertures have different sizes, shapes, and/or orientations.The pattern of apertures may be any of the various patterns describedherein or other suitable patterns. The second zone 4018 may comprise apattern of apertures, wherein at least two apertures of the pattern ofapertures have different sizes, shapes, and/or orientations. The patternof apertures may be any of the various patterns described herein orother suitable patterns. The patterns of apertures of the first zone4016 and the second zone 4018 may be different or the same.

FIG. 57 illustrates an example of a substrate having a first zone 4020and a second zone 4022. The front portion, F, may be positioned in afront portion of an absorbent article or a back portion of an absorbentarticle. The back portion, B, may be positioned in a front portion of anabsorbent article or a back portion of an absorbent article. The zones4020 and 4022 may be provided as two separate pieces of material thatare partially overlapped and joined or bonded together or may beprovided as one piece of material. The second zone 4022 may at leastpartially, or fully, surround the first zone 4020.

Still referring to FIG. 57, the first zone 4020 may comprise a patternof apertures, wherein at least two apertures of the pattern of apertureshave different sizes, shapes, and/or orientations. The pattern ofapertures may be any of the various patterns described herein or othersuitable patterns. The second zone 4022 may comprise a pattern ofapertures, wherein at least two apertures of the pattern of apertureshave different sizes, shapes, and/or orientations. The pattern ofapertures may be any of the various patterns described herein or othersuitable patterns. The patterns of apertures of the first zone 4020 andthe second zone 4022 may be different or the same.

Still referring to FIG. 57, the first zone 4020 may comprise a patternof apertures, wherein at least two apertures of the pattern of apertureshave different sizes, shapes, and/or orientations. The pattern ofapertures may be any of the various patterns described herein or othersuitable patterns. The second zone 4022 may comprise a plurality ofout-of-plane deformations as described above with reference to FIGS.2A-9B. The out-of-plane deformations may extend upwardly out of the pageor downwardly into the page

Still referring to FIG. 57, the second zone 4022 may comprise a patternof apertures, wherein at least two apertures of the pattern of apertureshave different sizes, shapes, and/or orientations. The pattern ofapertures may be any of the various patterns described herein or othersuitable patterns. The first zone 4020 may comprise a plurality ofout-of-plane deformations as described above with reference to FIGS.2A-9B. The out-of-plane deformations may extend upwardly out of the pageor downwardly into the page

Still referring to FIG. 57, the first zone 4020 may comprise a pluralityof out-of-plane deformations as described above with reference to FIGS.2A-9B. The out-of-plane deformations may extend upwardly out of the pageor downwardly into the page. The second zone 4022 may comprise aplurality of out-of-plane deformations as described above with referenceto FIGS. 2A-9B. The out-of-plane deformations may extend upwardly out ofthe page or downwardly into the page. The second zone 4022 may have adifferent or the same pattern, shape, size, and/or orientation of theout-of-plane deformations compared to the pattern, shape, size, and/ororientation of the first zone 4020.

Visual Texture

Apertures, aperture arrays, three-dimensional elements, tufts, printing,patterned adhesives, or any combinations of these “texture elements” mayimpart a variable visually observed texture in a nonwoven laminate.Variations in observable textures have been extensively studied in thepsychological and neurological sciences. Some small texture elements aremuch more readily (“instantly”) detected by the human visual perceptionsystem than others. Most texture patterns having similar “second order”(iso-dipole) statistics cannot be discriminated in a brief “flash”observation. However, exceptions to this (i.e., iso-dipole textureelements that are easily discriminated) have been defined and are knownin the literature as “textons”. Nonwoven laminates including textureelements forming texton shapes provide a way to create easilyrecognizable “zones” on a laminate or in an absorbent article, signalingregions having different functions, and/or providing strong cues as tocorrect product orientation on a wearer (e.g., front/back). Forms of thenonwoven laminates of the present disclosure may include textureelements forming texton shapes, including quasi-collinearity, cornerfeatures, and closure of local features. A reference is Julesz, B., etal, Visual Discrimination of Textures with Identical Third-OrderStatistics, Biological Cybernetics vol. 31, 1978, pp. 137-140).

Effective Open Area

A crimped fiber spunbond nonwoven web/nonwoven laminate of the presentinvention may have an Effective Open Area between about 1% to about 50%,about 5% to about 40%, about 8% to about 35%, about 10% to about 30%,about 10% to about 25%, or about 3% to about 15%, specifically includingall 0.1% increments within the specified ranges and all ranges formedtherein or thereby. All Effective Open Area percentages are determinedusing the Aperture Test described herein. Crimped fiber spunbondnonwoven webs/nonwoven laminates having a higher Effective Open Area mayhave utility as a topsheet or acquisition layer or system in anabsorbent article (more functional to absorbent bodily exudates), whilecrimped fiber spunbond nonwoven webs/nonwoven laminates having a lowerEffective Open Area may have utility as an outer cover of an absorbentarticle (more decorative or for breathability purposes). In some formsof the present invention, for hydrophilic webs—where a body contactingsurface is hydrophilic—the percentage open area can generally be less.For hydrophobic webs—where a body contacting surface is hydrophobic—thepercentage open area may be increased to ensure good acquisition rates.As an example, for a hydrophobic topsheet, the percentage open area canbe from about 5% to about 50%. As another example, for a hydrophilictopsheet, the percentage can be from about 1% to about 50%.

Effective Aperture Area

A crimped fiber spunbond nonwoven web/or nonwoven laminate may haveapertures having an Effective Aperture AREA in the range of about 0.1mm² to about 15 mm², 0.3 mm² to about 14 mm², 0.4 mm² to about 12 mm²,0.3 mm² to about 10 mm², 0.5 mm² to about 8 mm², 1.0 mm² to about 8 mm²,or about 1.0 mm² to about 5 mm², specifically including all 0.05 mmincrements within the specified ranges and all ranges formed therein orthereby. All Effective Aperture Areas are determined using the ApertureTest described herein. A plurality of the apertures in a crimped fiberspunbond nonwoven web/nonwoven laminate may be different in EffectiveAperture Areas. The Relative Standard Deviation (“RSD”) of the EffectiveAperture Areas may be at least about 20 percent, at least about 30percent, at least about 50 percent or at least about 55 percent, or atleast about 60 percent.

Interaperture Distance and Average Interaperture Distance

The crimped fiber spunbond nonwoven webs/nonwoven laminates may haveapertures that have an Average Interaperture Distance of less than about3.5 mm, less than about 3 mm, less than about 2.5 mm, less than about 2mm, less than about 1.5 mm, less than about 1 mm, in the range of about1 mm to about 6 mm, in the range of about 1 mm to about 5 mm, in therange from about 1 mm to about 4 mm, in the range from about 1 mm toabout 3.5 mm, in the range of about 1 mm to about 3 mm, in the range ofabout 1 mm to about 2.5 mm, in the range of about 2 mm to about 4 mm, inthe range of about 3.5 mm to about 10 mm, or in the range of about 0.08mm to about 11 mm, specifically reciting all 0.1 mm increments withinthe above-specified ranges and all ranges formed therein or thereby,according to the Interaperture Distance Test herein.

A crimped fiber spunbond nonwoven web/nonwoven laminate may haveInteraperture Distances, calculated according to the InterapertureDistance Test herein. The Interaperture Distances may have adistribution having a mean and a median. The mean may be greater than,different than, or less than the median. The difference between the meanand the median may be in the range of about 1% to about 25%, about 4% toabout 25%, about 5% to about 20%, about 8% to about 20%, about 4% toabout 15%, or about 1% to about 8%, for example, specifically recitingall 0.1% increments within the above specified ranges and all rangesformed therein or thereby. A first zone of an apertured web may haveInteraperture Distances. The Interaperture Distances of a first zone mayhave a first distribution having a first mean and a first median. Thefirst mean may be greater than, different than, or less than the firstmedian by the ranges set forth above in this paragraph. A second zone ofthe apertured web may have Interaperture Distances. The InterapertureDistances of the second zone may have a second distribution having asecond mean and a second median. The second mean may be greater than,less than, or different than the second median by the ranges set forthabove in this paragraph. A third zone of the apertured web may haveInteraperture Distances. The Interaperture Distances of the third zonemay have a third distribution having a third mean and a third median.The third mean may be greater than, different than, or less than thethird median by the ranges set forth above in this paragraph. The first,second, and third means may be the same or different. The first, second,and third medians may be the same or different. The first, second, andthird zones may be in a topsheet, a topsheet layer, an acquisitionlayer, an outercover, an outercover layer, or any other component of anabsorbent article or other consumer products.

In other instances, a first portion of an absorbent article or otherconsumer product may have a first apertured web that has InterapertureDistances, according to the Interaperture Distance Test herein. TheInteraperture Distances of the first portion have a first distribution.A second portion of an absorbent article or other consumer product mayhave a second apertured web that has Interaperture Distances, accordingto the Interaperture Distance Test herein. The Interaperture Distancesof the second portion have a second distribution. A third portion of anabsorbent article or other consumer product may have a third aperturedweb that has Interaperture Distances, according to the InterapertureDistance Test herein. The Interaperture Distances of the third portionhave a third distribution. The first, second, and third distributionsmay be the same or different. The first distribution may have a firstmean and a first median. The first mean may be greater than, less than,or different than the first median in the range of about 1% to about25%, about 4% to about 25%, about 5% to about 20%, about 8% to about20%, about 4% to about 15%, or about 1% to about 8%, for example,specifically reciting all 0.1% increments within the above-specifiedranges and all ranges formed therein or thereby. The second distributionmay have a second mean and a second median. The second mean may begreater than, different than, or less than the second median by theranges set forth above in this paragraph. The third distribution mayhave a second mean and a second median. The second mean may be greaterthan, different than, or less than the second median by the ranges setforth above in this paragraph. The first, second, and third means may bethe same or different. The first, second, and third medians may be thesame or different. The Relative Standard Deviation (RSD) of theInteraperture Distances may be at least 25%, at least about 35%, atleast about 40%, at least about about 50%, or at least about 55%. TheMaximum Interaperture Distance in a given web or pattern may be at leastabout 5 mm, at least about 8 mm, at least about 10 mm, or at least about11 mm.

Average Absolute Feret Angle and Absolute Feret Angle

A crimped fiber spunbond nonwoven web/nonwoven laminate may have one ormore apertures having an Absolute Ferret Angle, according to theAbsolute Feret Angle Test, of at least about 2 degrees, 5 degrees, 15degrees, at least about 18 degrees, at least about 20 degrees, at leastabout 22 degrees, at least about 25 degrees, at least about 30 degrees,at least about 35 degrees, at least about 40 degrees, at least about 45degrees, at least about 50 degrees, at least about 55 degrees, at leastabout 60 degrees, or in the range of about 2 degrees to about 80degrees, in the range of about 5 degrees to about 75 degrees, in therange of about 10 degrees to about 70 degrees, or in the range of about15 degrees to about 65 degrees, specifically reciting all 0.1 degreesincrements within the above-specified ranges and all ranges formedtherein or thereby.

A crimped fiber spunbond nonwoven web/nonwoven laminate may have aplurality of apertures having an Average Absolute Ferret Angle,according to the Average Absolute Feret Angle Test, of at least about 2degrees, 5 degrees, 15 degrees, at least about 18 degrees, at leastabout 20 degrees, at least about 22 degrees, at least about 25 degrees,at least about 30 degrees, at least about 35 degrees, at least about 40degrees, at least about 45 degrees, at least about 50 degrees, at leastabout 55 degrees, at least about 60 degrees, or in the range of about 2degrees to about 80 degrees, in the range of about 5 degrees to about 75degrees, in the range of about 10 degrees to about 70 degrees, or in therange of about 15 degrees to about 65 degrees, specifically reciting all0.1 degrees increments within the above-specified ranges and all rangesformed therein or thereby. These apertures may all be within a singlerepeat unit of the apertured web.

At least two, at least 3, at least 4, at least 5, at least 6, at least7, at least 8, at least 9, or at least 10 of the apertures in anapertured web, or a repeat unit of an apertured web, may each have adifferent Absolute Feret Angle, according to the Absolute Feret AngleTest herein. In other instances, some of the apertures may have AbsoluteFeret Angles that are the same, while other of the apertures may haveAbsolute Feret Angles that are different. In addition to havingdifferent Absolute Feret Angles, the at least two, at least 3, at least4, at least 5, at least 6, at least 7, at least 8, at least 9, or atleast 10 apertures may have different sizes and/or shapes. At least someof the at least two, at least 3, at least 4, at least 5, at least 6, atleast 7, at least 8, at least 9, or at least 10 apertures may also havethe same size and/or shape, while having different Absolute FeretAngles.

Apertures oriented at ferret angles greater than zero relative to themachine direction may have a higher aspect ratio than apertures that arealigned in the machine direction or vice versa. Apertured webs havingelongated apertures oriented at different ferret angles may provideliquid bodily exudate handling benefits when the apertured web is usedas a topsheet in an absorbent article. For example, fluid run-off may bereduced in the front or back of the absorbent article when the aperturesare not all aligned in the machine direction, but instead are orientedat an angle relative to the machine direction (e.g., about 30 degrees,about 45 degrees, or even about 90 degrees) as the apertures can morereadily acquire the liquid bodily exudates. Therefore, it may bedesirable to have the central longitudinal axes of the elongatedapertures oriented at multiple different ferret angles in order to mosteffectively acquire liquid bodily exudates running along the surface ofthe apertured web and prevent, or at least inhibit, run-off and soilingof garments.

In some forms of the present invention, a crimped fiber spunbondnonwoven web/nonwoven laminate may comprise a plurality of apertureswherein a first portion of the apertures have an Absolute Feret angle ofless than about 20 degrees and wherein a second portion of the apertureshave an Absolute Feret angle of greater than about 20 degrees. In someforms, the first portion may comprise about 50% of the plurality ofapertures. In some forms, the first portion may comprise about 40% ofthe plurality of apertures. In some forms, a first plurality ofapertures may comprise more apertures than a second plurality ofapertures by a ratio of about 3 to 1 or about 5 to 1. In some forms, thefirst plurality of apertures may be disposed about the second pluralityof apertures.

Crimped fiber spunbond nonwoven webs/nonwoven laminates having apertureshaving different feret angles may provide liquid bodily exudate handlingbenefits when used as a topsheet in an absorbent article. For example,fluid run-off may be reduced in the front or back of the absorbentarticle when all of the apertures are not all aligned in the machinedirection, but instead are oriented at an angle relative to the machinedirection (e.g., about 30 degrees, about 45 degrees, or even about 90degrees) as the apertures can more readily acquire the liquid bodilyexudates. Therefore, it may be desirable to have apertures oriented atmultiple different feret angles in order to most effectively acquireliquid bodily exudates running along the surface of the crimped fiberspunbond nonwoven web/nonwoven laminate of the present invention andprevent, or at least inhibit, run-off and soiling of garments.

In some examples, a pattern of overbonds, each of which is orientedsolely in the machine direction, or substantially in the machinedirection (i.e., +/−5 degrees or less from the machine direction), maybe used to create a crimped fiber spunbond nonwoven web/nonwovenlaminate with apertures having central longitudinal axes that are notall oriented in the machine direction or, stated another way, that areangled more than 5 degrees with respect to the machine direction. Thenonwoven laminate 2200 of FIGS. 31-32 may have some apertures 2212having a central longitudinal axis, L, having an angle with respect tothe machine direction. The angle may be from about 5 degrees to about 70degrees with respect to the machine direction, specifically reciting all0.5 degree increments within the specified range and all ranges formedtherein. Some of the apertures 2212 in the nonwoven laminate 2200 mayalso have a central longitudinal axis, L1, that extends parallel to, orsubstantially parallel to (e.g., +/− less than 5 degrees), the machinedirection. The cross directional stretching step or steps describedherein may be used to create the apertures and to orient the centrallongitudinal axes, L, of at least some of the apertures in a directionnot parallel to, or substantially parallel to, the machine direction. Atleast some of the apertures in a crimped fiber spunbond nonwovenweb/nonwoven laminate having their central longitudinal axes notparallel to, or substantially parallel to, the machine direction mayhave a first plurality of apertures having central longitudinal axesextending in a first direction with respect to the machine direction anda second plurality of apertures having central longitudinal axesextending at a second, different direction relative to the machinedirection. The first and second directions may be 30 degrees and −30degrees, respectively, 10 degrees and 20 degrees respectively, or −20degrees and 30 degrees respectively, to provide a few examples. Those ofskill in the art will recognize that angles relative to the machined arealso within the scope of the present disclosure.

The apertures in a crimped fiber spunbond nonwoven web or nonwovenlaminate having apertures generally parallel to the machine directionand produced by machine direction overbonds may be more open (i.e., havea lower aspect ratio) than they would have been if the overbonds hadbeen oriented at an angle (5 degrees or more) with respect to themachine direction. Overbonds oriented at an angle with respect to themachine direction typically produce apertures having higher aspectratios post cross directional stretching that are less open.

Additional suitable overbond patterns are disclosed in U.S. ApplicationSer. No. 62/177,405 filed on Mar. 13, 2015, with regard to FIGS. 55-116which show schematic representations of a variety of overbond patterns.Those of skill in the art will recognize that other suitable overbondpatterns are also within the scope of the present disclosure, along withvariations of the illustrated patterns. Additional overbond patterns aredisclosed with regard to FIGS. 58 and 59.

As shown in FIG. 58, a suitable overbond pattern for use with thecrimped fiber spunbond nonwoven webs/nonwoven laminates of the presentinvention may comprise an array of overbonds disposed in several groups.For example, a first plurality of overbond sites 6010 may surround asecond plurality of overbond sites 6020. Generally, the second pluralityof overbond sites 6020 may be arranged to form (subsequent toprocessing) apertured indicia. As shown, hearts.

As shown in FIG. 59, another suitable overbond pattern for use with thenonwoven webs of the present invention may comprise a first plurality ofoverbond sites 6010B, a second plurality of overbond sites 6020B, and athird plurality of overbond sites 6030B. As shown, the first pluralityof overbond sites 6010B may, at least in part, surround the secondplurality of overbond sites 6020B. Much like the overbond pattern ofFIG. 58, the overbond sites 6010B are shown generally parallel to alongitudinal axis (not shown). The resulting apertures will generally bealigned with respect to the longitudinal axis. Additionally, the thirdplurality of overbond sites 6030B is angled with respect to thelongitudinal axis at a first angle. The second plurality of overbondsites 6020B is angled with respect to the longitudinal axis at a secondangle. In the form shown, the first angle and the second angle aredifferent. The first and the second angle may be any of the rangesdescribed heretofore with regard to the angles of the apertures.

Similarly, additional suitable aperture patterns for crimped fiberspunbond nonwoven webs/nonwoven laminates of the present invention aredisclosed in U.S. Application Ser. No. 62/177,405 filed on Mar. 13,2015, with regard to FIGS. 117-162 which show schematic representationsof a variety of overbond patterns. In these Figures, the white areasrepresent non-apertured areas (land areas) and the black areas representapertured areas. Those of skill in the art will recognize that othersuitable patterns of nonwoven laminates are also within the scope of thepresent disclosure, along with variations of the illustrated patterns.

Additionally, in some forms of the present invention, the nonwoven webof the present invention may be produced and subsequently provided to adisposable absorbent article converting line. However, in some forms, amanufacturer may obtain a crimped fiber spunbond nonwoven web whichcomprises apertures as described herein. In some forms, a manufacturermay obtain a nonwoven web which comprises out-of-plane deformations asdescribed herein. In some forms, a manufacturer may obtain a nonwovenweb which comprises overbonds as described herein. Similarly, amanufacturer may obtain a supply roll which comprises a laminatecomprising a crimped fiber spunbond nonwoven web and another web asdescribed herein.

Overbonds are typically a melt-stabilized area in a material, e.g.nonwoven, which has a stabilized film-like form.

Aperture Aspect Ratio and Area

The apertures of the crimped fiber spunbond nonwoven webs/nonwovenlaminates of the present invention may have an aspect ratio of greaterthan one, for example, greater than two, greater than 3, greater than 5,or greater than 10, but typically less than 15. The aperture patterns inthe crimped fiber spunbond nonwoven web/nonwoven laminate may compriseapertures having more than one aspect ratio, such as two or moredistinct populations or having a substantially continuous distributionof aspect ratios having a slope greater than zero. Additionally, theaperture patterns may comprise apertures with more than two effectiveaperture area, either as two or more distinct populations or as adistribution of aperture areas having a slope greater than zero. TheRelative Standard Deviation (RSD) of the aperture aspect ratios may beat least about 15%, at least about 25%, at least about 30%, or at leastabout 40%, or at least about 45%.

Fused Portions

Referring to FIG. 60, areas surrounding at least a portion of anaperture 2212 in a nonwoven laminate of the present disclosure maycomprise one or more fused portions 5000. The fused portions 5000 may atleast partially surround the apertures 2212, or fully surround theapertures 2212. The fused portions 5000 may surround at least 25% of aperimeter of the apertures 2212 up to about 100% of the perimeter of theapertures 2212. In some instances, the fused portions 5000 may be formedon the lateral sides of the apertures 2212 and not on the leading andtrailing edges of the apertures 12. The fused portions 5000 are believedto be formed during the overbonding step and are believed to addstrength to the nonwoven laminates and/or bond layers together.

Packages

Absorbent articles comprising the crimped fiber spunbond nonwovenweb/nonwoven laminate of the present invention may be placed intopackages. The packages may comprise polymeric films and/or othermaterials. Graphics or indicia relating to properties of the absorbentarticles may be formed on, positioned on, and/or placed on outerportions of the packages. Each package may comprise one or moreabsorbent articles. The absorbent articles may be packed undercompression so as to reduce the size or height of the packages whilestill providing an adequate amount of absorbent articles per package.

Accordingly, packages of the absorbent articles according to the presentdisclosure may have an in-bag stack height of less than about 80 mm,less than about 78 mm, or less than about 76 mm, according to the In-BagStack Height Test described herein. Alternatively, packages of theabsorbent articles of the present disclosure may have an in-bag stackheight of from about 72 mm to about 80 mm or from about 74 mm to about78 mm, specifically reciting all 0.5 mm increments within the specifiedranges and all ranges formed therein or thereby, according to theIn-Back Stack Height Test described herein. Further details regardingin-back stack height are disclosed in U.S. Pat. No. 8,585,666, toWeisman et al., issued on Nov. 19, 2013.

Test Methods

Opacity Method

Opacity by contrast ratio measurements are made using a 0°/45°spectrophotometer suitable for making standard CIE L*a*b* colormeasurements (e.g. Hunterlab Labscan XE spectrophotometer, HunterAssociates Laboratory Inc., Reston Va. or equivalent). The diameter ofthe instrument's measurement port should be chosen such that only theregion of interest is included within the measurement port. Analyses areperformed in a room controlled at about 23° C.±2 C.° and 50%±2% relativehumidity. Samples are conditioned at the same condition for 2 hoursbefore testing.

Calibrate the instrument per the vender instructions using the standardblack and white tiles provided by the vendor. Set the spectrophotometerto use the CIE XYZ color space, with a D65 standard illumination and 10°observer. Using cryogenic spray and scissors carefully excise thespecimen from the article for testing. Place the specimen flat againstthe instrument with the outward facing surface toward thespectrophotometer's measurement port and the region of interest withinthe port. Ensure that no tears, holes or apertures are within themeasurement port. Place the white standard tile onto the opposingsurface of the specimen such that it completely covers the measurementport. Take a reading for XYZ and record to 0.01 units. Without movingthe specimen, remove the white plate and replace it with the blackstandard plate. Take a second reading for XYZ and record to 0.01 units.Repeat this procedure at a corresponding site for a total of ten (10)replicate specimens.

Opacity is calculated by dividing the Y value measured using the blacktile as backing, divided by the Y value measured using the white tile asbacking, then multiplying the ratio by 100. Record the opacity value tothe nearest 0.01%. Calculate opacity for the 10 replicates and reportthe average opacity to the nearest 0.01%.

Aperture/Feret Angle Test

Aperture dimensions, Effective Open Area and Inter-Aperture Distancemeasurements are obtained from specimen images acquired using a flatbedscanner. The scanner is capable of scanning in reflectance mode at aresolution of 6400 dpi and 8 bit grayscale (a suitable scanner is anEpson Perfection V750 Pro from Epson America Inc., Long Beach Calif. orequivalent). The scanner is interfaced with a computer running an imageanalysis program (a suitable program is ImageJ v. 1.47 or equivalent,National Institute of Health, USA). The specimen images are distancecalibrated against an acquired image of a ruler certified by NIST. Asteel frame is used to mount the specimen, which is then backed with ablack glass tile (P/N 11-0050-30, available from HunterLab, Reston, Va.)prior to acquiring the specimen image. The resulting image is thenthreshold, separating open aperture regions from specimen materialregions, and analyzed using the image analysis program. All testing isperformed in a conditioned room maintained at about 23±2° C. and about50±2% relative humidity.

Sample Preparation:

To obtain a specimen, tape the absorbent article to a rigid flat surfacein a planar configuration. Any leg elastics may be cut to facilitatelaying the article flat. A rectilinear steel frame (100 mm square, 1.5mm thick with an opening 60 mm square) is used to mount the specimen.Take the steel frame and place double-sided adhesive tape on the bottomsurface surrounding the interior opening. Remove the release paper ofthe tape, and adhere the steel frame to the apertured layer of thearticle. Align the frame so that it is parallel and perpendicular to themachine direction (MD) and cross direction (CD) of the apertured layer.Using a razor blade excise the apertured layer from the underlyinglayers of the article around the outer perimeter of the frame. Carefullyremove the specimen such that its longitudinal and lateral extension ismaintained to avoid distortion of the apertures. A cryogenic spray (suchas Cyto-Freeze, Control Company, Houston Tex.) can be used to remove thespecimen from the underlying layers if necessary. Five replicatesobtained from five substantially similar articles are prepared foranalysis. If the aperture layer of interest is too small to accommodatethe steel frame, reduce the frame dimensions accordingly to accomplishthe goals of removal of the specimen without distortion of the apertureswhile leaving an opening of sufficient size to allow for scanning asignificant portion of the apertured layer. An apertured substrate rawmaterial is prepared for testing by extending or activating it under thesame process conditions, and to the same extent, as it would be for useon the absorbent article, and then in its extended state adhering it tothe steel frame as described above for testing. Condition the samples atabout 23° C.±2 C.° and about 50%±2% relative humidity for 2 hours priorto testing.

Image Acquisition:

Place the ruler on the scanner bed, oriented parallel to the sides ofthe scanner glass, and close the lid. Acquire a calibration image of theruler in reflectance mode at a resolution of 6400 dpi (approximately 252pixels per mm) and 8 bit grayscale, with the field of view correspondingto the dimensions of the interior of the steel frame. Save thecalibration image as an uncompressed TIFF format file. Lift the lid andremove the ruler. After obtaining the calibration image, all specimensare scanned under the same conditions and measured based on the samecalibration file. Next, place the framed specimen onto the center of thescanner bed, lying flat, with the outward facing surface of the specimenfacing the scanner's glass surface. Orient the specimen so that sides ofthe frame are aligned parallel with and perpendicular to the sides ofthe scanner's glass surface, so that the resulting specimen image willhave the MD vertically running from top to bottom. Place the black glasstile on top of the frame covering the specimen, close the lid andacquire a scanned image. Scan the remaining four replicates in likefashion. If necessary, crop all images to a rectangular field of viewcircumscribing the apertured region, and resave the files.

Effective Open Area Calculation:

Open the calibration image file in the image analysis program andperform a linear distance calibration using the imaged ruler. Thisdistance calibration scale will be applied to all subsequent specimenimages prior to analysis. Open a specimen image in the image analysisprogram and set the distance scale. View the 8 bit histogram (0 to 255,with one bin per GL) and identify the gray level (GL) value for theminimum population located between the dark pixel peak of the apertureholes and the lighter pixel peak of the specimen material. Threshold theimage at the minimum gray level value to generate a binary image. In thebinary image the apertures appear as black, with a GL value of 255, andspecimen as white, with a GL value of 0.

Using the image analysis program, analyze each of the discrete apertureregions. Measure and record all of the individual aperture areas to thenearest 0.01 mm², including partial apertures along the edges of theimage. Discard any apertures with an area less than 0.3 mm². Apertureshaving a lower area than 0.3 mm² may prove difficult to measureparticularly when stray fibers cross the boundary of the aperture. Andsuch apertures with that small of an area are considered to contributeinsignificantly to the Effective Open Area. Sum the remaining apertureareas (including whole and partial apertures), divide by the total areaincluded in the image and multiply by 100. Record this value as the %Effective Open Area to the nearest 0.01%.

In like fashion, analyze the remaining four specimen images. Calculateand report the average % effective area values to the nearest 0.01% forthe five replicates.

Effective Aperture Area and Absolute Feret Angle:

Open the calibration image (containing the ruler) file in the imageanalysis program. Resize the resolution of the original image from 6400dpi to 640 dpi (approximately 25.2 pixels per mm) using a bicubicinterpolation. Perform a linear distance calibration using the imagedruler. This distance calibration scale will be applied to all subsequentspecimen images prior to analysis. Open a specimen image in the imageanalysis program. Resize the resolution of the original image from 6400dpi to 640 dpi (approximately 25.2 pixels per mm) using a bicubicinterpolation. Set the distance scale. View the 8 bit histogram (0 to255, with one bin per GL) and identify the gray level (GL) value for theminimum population located between the dark pixel peak of the apertureholes and the lighter pixel peak of the specimen material. Threshold theimage at the minimum gray level value to generate a binary image. In thebinary image the apertures appear as black, with a GL value of 255, andspecimen as white, with a GL value of 0. Next, two morphologicaloperations are performed on the binary image. First, a closing (adilation operation followed by an erosion operation, iterations=1, pixelcount=1), which removes stray fibers within an aperture hole. Second, anopening (an erosion operation followed by a dilation operation,iterations=1, pixel count=1), which removes isolated black pixels. Padthe edges of the image during the erosion step to ensure that blackboundary pixels are maintained during the operation. Lastly, fill anyremaining voids enclosed within the black aperture regions.

Using the image analysis program, analyze each of the discrete apertureregions. During the analysis exclude measurements of partial aperturesalong the edges of the image, so that only whole apertures are measured.Measure and record all of the individual aperture areas, perimeters,feret diameters (length of the apertures) along with its correspondingangle of orientation in degrees from 0 to 180, and minimum feretdiameters (width of the apertures). Record the measurements for each ofthe individual aperture areas to the nearest 0.01 mm², the perimetersand feret diameters (length and width), to the nearest 0.01 mm, andangles to the nearest 0.01 degree. Discard any apertures with an arealess than 0.3 mm². Record the number of remaining apertures, divide bythe area of the image and record as the Aperture Density value. Theangle of orientation for an aperture aligned with the MD (vertical inthe image) will have an angle of 90 degrees. Apertures with a positiveslope, increasing from left to right, will have an angle between zeroand 90 degrees. Apertures with a negative slope, decreasing from left toright, will have an angle between 90 and 180 degrees. Using theindividual aperture angles calculate an Absolute Aperture Angle bysubtracting 90 degrees from the original angle of orientation and takingits absolute value. In addition to these measurements, calculate anAspect Ratio value for each individual aperture by dividing the aperturelength by its width. Repeat this analysis for each of the remaining fourreplicate images. Calculate and report the statistical mean and standarddeviation for each of the effective aperture dimension measurementsusing all of the aperture values recorded from the replicates. Calculateand report the % relative standard deviation (RSD) for each of theaperture dimension measurements by dividing the standard deviation bythe mean and multiplying by 100.

Inter-Aperture Distance Measurements:

The average, standard deviation, median, and maximum distance betweenthe apertures can be measured by further analyzing the binary image thatwas analyzed for the aperture dimension measurements. First, obtain aduplicate copy of the resized binary image following the morphologicaloperations, and using the image analysis program, perform a Voronoioperation. This generates an image of cells bounded by lines of pixelshaving equal distance to the borders of the two nearest patternapertures, where the pixel values are outputs from a Euclidian distancemap (EDM) of the binary image. An EDM is generated when eachinter-aperture pixel in the binary image is replaced with a value equalto that pixel's distance from the nearest pattern aperture. Next, removethe background zeros to enable statistical analysis of the distancevalues. This is accomplished by using the image calculator to divide theVoronoi cell image by itself to generate a 32-bit floating point imagewhere all of the cell lines have a value of one, and the remaining partsof the image are identified as Not a Number (NaN). Lastly, using theimage calculator, multiply this image by the original Voronoi cell imageto generate a 32-bit floating point image where the distance valuesalong the cell lines remain, and all of the zero values have beenreplaced with NaN. Next, convert the pixel distance values into actualinter-aperture distances by multiplying the values in the image by thepixel resolution of the image (approximately 0.04 mm per pixel), andthen multiply the image again by 2 since the values represent themidpoint distance between apertures. Measure and record the mean,standard deviation, median and maximum inter-aperture distances for theimage to the nearest 0.01 mm. Repeat this procedure for all replicateimages. Calculate the % relative standard deviation (RSD) for theinter-aperture distance by dividing the standard deviation by the meanand multiplying by 100.

Land Area Light Transmission Method

The land area light transmission method measures the average amount oflight transmitted through specific regions of a specimen. A calibratedlight transmission image is obtained using a flatbed scanner. A binarymask is generated to separate discrete aperture regions from thesurrounding land area. The binary mask is then registered to the lighttransmission image, and used to exclude the apertures from the land areain the light transmission image. This enables the average lighttransmission value for the land area to be calculated.

Sample Preparation:

To obtain a specimen, tape the absorbent article to a rigid flat surfacein a planar configuration. Any leg elastics may be cut to facilitatelaying the article flat. A rectilinear steel frame (100 mm square, 1.5mm thick with an opening 60 mm square) is used to mount the specimen.Take the steel frame and place double-sided adhesive tape on the bottomsurface surrounding the interior opening. Remove the release paper ofthe tape, and adhere the steel frame to the apertured layer of thearticle. Align the frame so that it is parallel and perpendicular to themachine direction (MD) and cross direction (CD) of the apertured layer.Using a razor blade excise the apertured layer from the underlyinglayers of the article around the outer perimeter of the frame. Carefullyremove the specimen such that its longitudinal and lateral extension ismaintained to avoid distortion of the apertures. A cryogenic spray (suchas Cyto-Freeze, Control Company, Houston Tex.) can be used to remove thespecimen from the underlying layers if necessary. Five replicatesobtained from five substantially similar articles are prepared foranalysis. If the aperture layer of interest is too small to accommodatethe steel frame, reduce the frame dimensions accordingly to accomplishthe goals of removal of the specimen without distortion of the apertureswhile leaving an opening of sufficient size to allow for scanning asignificant portion of the apertured layer. Condition the samples atabout 23° C.±2 C.° and about 50%±2% relative humidity for 2 hours priorto testing.

Light Transmission Image

The light transmission measurement is based on the CIE L*a*b* colorsystem (CIELAB). A flatbed scanner capable of scanning a minimum of 24bit color at 800 dpi and has manual control of color management (asuitable scanner is an Epson Perfection V750 Pro from Epson AmericaInc., Long Beach Calif. or equivalent) is used to acquire images. Thescanner is interfaced with a computer running color management software(suitable color management software is MonacoEZColor available fromX-Rite Grand Rapids, Mich. or equivalent). The scanner is calibratedagainst a color transparency target and corresponding reference filecompliant with ANSI method IT8.7/1-1993 using the color managementsoftware to construct a calibrated color profile. The resultingcalibrated scanner profile is used to color correct an image from a testspecimen within an image analysis program that supports sampling in CIEL*a*b* (a suitable program is Photoshop S4 available from Adobe SystemsInc., San Jose, Calif. or equivalent). All testing is performed in aconditioned room maintained at about 23±2° C. and about 50±2% relativehumidity.

Turn on the scanner for 30 minutes prior to calibration. Deselect anyautomatic color correction or color management options that may beincluded in the scanner software. If the automatic color managementcannot be disabled, the scanner is not appropriate for this application.Place the IT8 target face down onto the scanner glass, close the scannerlid, acquire an image at 200 dpi and 24 bit color and remove the IT8target. Open the image file on the computer with the color managementsoftware. Follow the recommended steps within the color managementsoftware to create and export a calibrated color profile. These stepsmay include, ensuring that the scanned image is oriented and croppedcorrectly. The calibrated color profile must be compatible with theimage analysis program. The color management software uses the acquiredimage to compare with the included reference file to create and exportthe calibrated color profile. After the profile is created the scanresolution (dpi) for test specimens can be changed, but all othersettings must be kept constant while imaging specimens.

Open the scanner lid and place the specimen flat against the scannerglass with the outward facing surface facing the glass. Acquire andimport a scan of the specimen region within the interior of the frameinto the image analysis software at 24 bit color and at 800 dpi intransparency mode. If necessary, crop image to a rectangular field ofview circumscribing the apertured region. Transparency mode illuminatesthe specimen from one side with the sensor capturing the image from theopposite side. Assign the calibrated color profile to the image andchange the color space mode to L*a*b* Color corresponding to the CIEL*a*b* standard. This produces a color corrected image for analysis.Save this color corrected image in an uncompressed format, such as aTIFF file.

Land Area Mask

The boundaries of the apertured areas and land area are identified bythresholding the L* channel image to generate a binary image, separatingapertured areas from the surrounding land area. This binary image willthen be used as a mask on the corresponding light transmission image tomeasure the average Light Transmission Value of only the land area.

To do this, first open the color corrected light transmission image inthe image analysis software. To generate the land area mask, firstseparate the L*, a* and b* channels, and select only the L* channel foranalysis. The L* channel represents the “Lightness” of the image and hasvalues that range from 0-100. Threshold the L* channel image at a valueof 90 to generate a binary image. By thresholding at the level describedabove, a binary mask image is produced with the discrete aperture areasassigned one value, and the surrounding land area assigned a differentvalue. For example, the discrete aperture areas could appear black, andthe surrounding land area could appear white. Save this binary maskimage in an uncompressed format, such as a TIFF file.

Analysis of Light Transmission Image

Open both the color corrected light transmission image and thecorresponding binary mask image in the image analysis software. Toanalyze the specimen light transmission image, first separate the L*, a*and b* channels, and select only the L* channel for analysis. Registerthe light transmission image and the binary mask image to each other.Use the binary mask to exclude the apertures from the light transmissionimage, and calculate an average L* value (Light Transmission Value) forthe remaining surrounding land area. Record this value as the Land AreaLight Transmission Value to the nearest 0.1 units. In like fashion,repeat this procedure on all of the replicate specimens. Calculate andreport the average of the five individual Land Area Light TransmissionValues to the nearest 0.1 units.

Basis Weight Method

Basis weight of the crimped fiber spunbond nonwoven web/nonwovenlaminate of the present invention may be determined by several availabletechniques, but a simple representative technique involves taking anabsorbent article or other consumer product, removing any elastic whichmay be present and stretching the absorbent article or other consumerproduct to its full length. A punch die having an area of 45.6 cm² isthen used to cut a piece of the nonwoven laminate (e.g., topsheet, outercover) from the approximate center of the absorbent article or otherconsumer product in a location which avoids to the greatest extentpossible any adhesive which may be used to fasten the nonwoven laminateto any other layers which may be present and removing the nonwovenlaminate from other layers (using cryogenic spray, such as Cyto-Freeze,Control Company, Houston, Tex., if needed). The sample is then weighedand dividing by the area of the punch die yields the basis weight of thenonwoven laminate. Results are reported as a mean of 5 samples to thenearest 0.1 cm².

In-Bag Stack Height Test

The in-bag stack height of a package of absorbent articles is determinedas follows:

Equipment

A thickness tester with a flat, rigid horizontal sliding plate is used.The thickness tester is configured so that the horizontal sliding platemoves freely in a vertical direction with the horizontal sliding platealways maintained in a horizontal orientation directly above a flat,rigid horizontal base plate. The thickness tester includes a suitabledevice for measuring the gap between the horizontal sliding plate andthe horizontal base plate to within ±0.5 mm. The horizontal slidingplate and the horizontal base plate are larger than the surface of theabsorbent article package that contacts each plate, i.e. each plateextends past the contact surface of the absorbent article package in alldirections. The horizontal sliding plate exerts a downward force of850±1 gram-force (8.34 N) on the absorbent article package, which may beachieved by placing a suitable weight on the center of thenon-package-contacting top surface of the horizontal sliding plate sothat the total mass of the sliding plate plus added weight is 850±1grams.

Definitions

As illustrated in FIG. 61, a package 9500 defines an interior space 9502and comprises a plurality of absorbent articles 9504. The absorbentarticles are in a stack 9506. The package has a package width 9508. Thepackage width is defined as the maximum distance between the two highestbulging points along the same compression stack axis of the absorbentarticle package 9500.In-Bag Stack Height=(Package Width/Pad Count Per Stack)×10 absorbentarticles.Test Procedure

Absorbent article packages are equilibrated at 23±2° C. and 50±5%relative humidity prior to measurement.

The horizontal sliding plate is raised and an absorbent article packageis placed centrally under the horizontal sliding plate in such a waythat the absorbent articles within the package are in a horizontalorientation. Any handle or other packaging feature on the surfaces ofthe package that would contact either of the plates is folded flatagainst the surface of the package so as to minimize their impact on themeasurement. The horizontal sliding plate is lowered slowly until itcontacts the top surface of the package and then released. The gapbetween the horizontal plates is measured to within ±0.5 mm ten secondsafter releasing the horizontal sliding plate. Five identical packages(same size packages and same absorbent articles counts) are measured andthe arithmetic mean is reported as the package width. The “In-Bag StackHeight”=(package width/absorbent article count per stack)×10 iscalculated and reported to within ±0.5 mm.

HLB (Hydrophilic/Lipophilic Balance)

The term “HLB” or “HLB value” of a surfactant refers to theHydrophilic-Lipophilic Balance and is a measure of the degree to whichit is hydrophilic or lipophilic, determined by calculating values forthe different regions of the molecule. For nonionic surfactants theHLB=20*Mb/M, where M is the molecular mass of the whole molecule and Mbis the molecular mass of the hydrophilic portion of the Molecule. An HLBvalue of 0 corresponds to a completely lipidphilic/hydrophobic molecule,and a value of 20 corresponds to a completely hydrophilic/lipidphobicmolecule. The above represents the Griffin method of HLB calculationwhich is well known in the art.

Fiber Diameter and Denier Test

The diameter of fibers in a sample of a nonwoven substrate is determinedby using a Scanning Electron Microscope (SEM) and image analysissoftware. A magnification of 500 to 10,000 times is chosen such that thefibers are suitably enlarged for measurement. The samples are sputteredwith gold or a palladium compound to avoid electric charging andvibrations of the fibers in the electron beam. A manual procedure fordetermining the fiber diameters is used. Using a mouse and a cursortool, the edge of a randomly selected fiber is sought and then measuredacross its width (i.e., perpendicular to fiber direction at that point)to the other edge of the fiber. For non-circular fibers, the area of thecross-section is measured using the image analysis software. Theeffective diameter is then calculated by calculating the diameter as ifthe found area was that of a circle. A scaled and calibrated imageanalysis tool provides the scaling to get actual reading in micrometers(μm). Several fibers are thus randomly selected across the sample of thenonwoven substrate using the SEM. At least two specimens from thenonwoven substrate are cut and tested in this manner. Altogether, atleast 100 such measurements are made and then all data is recorded forstatistical analysis. The recorded data is used to calculate average(mean) of the fiber diameters, standard deviation of the fiberdiameters, and median of the fiber diameters. Another useful statisticis the calculation of the amount of the population of fibers that isbelow a certain upper limit. To determine this statistic, the softwareis programmed to count how many results of the fiber diameters are belowan upper limit and that count (divided by total number of data andmultiplied by 100%) is reported in percent as percent below the upperlimit, such as percent below 1 micrometer diameter or %-submicron, forexample.

If the results are to be reported in denier, then the followingcalculations are made.Fiber Diameter in denier=Cross-sectional area (in m2)*density (inkg/m3)*9000 m*1000 g/kg.

For round fibers, the cross-sectional area is defined by the equation:A=π*(D/2){circumflex over ( )}2.The density for polypropylene, for example, may be taken as 910 kg/m3.

Given the fiber diameter in denier, the physical circular fiber diameterin meters (or micrometers) is calculated from these relationships andvice versa. We denote the measured diameter (in microns) of anindividual circular fiber as D.

In case the fibers have non-circular cross-sections, the measurement ofthe fiber diameter is determined as and set equal to the hydraulicdiameter, as discussed above.

Specific Surface Area

The specific surface area of the nonwoven substrates of the presentdisclosure is determined by Krypton gas adsorption using a MicromeriticASAP 2420 or equivalent instrument, using the continuous saturationvapor pressure (Po) method (according to ASTM D-6556-10), and followingthe principles and calculations of Brunauer, Emmett, and Teller, with aKr-BET gas adsorption technique including automatic degas and thermalcorrection. Note that the specimens should not be degassed at 300degrees Celsius as the method recommends, but instead should be degassedat room temperature. The specific surface area should be reported inm²/g.

Obtaining Samples of Nonwoven Substrates

Each surface area measurement is taken from a specimen totaling 1 g ofthe nonwoven substrate of the present disclosure. In order to achieve 1g of material, multiple specimens may be taken from one or moreabsorbent articles, one or more packages, or one or more wipes,depending on whether absorbent articles, packages, or wipes are beingtested. Wet wipe specimens will be dried at 40 degrees C. for two hoursor until liquid does not leak out of the specimen under light pressure.The specimens are cut from the absorbent articles, packages, or wipes(depending on whether absorbent articles, packages, or wipes are beingtested) in areas free of, or substantially free of, adhesives usingscissors. An ultraviolet fluorescence analysis cabinet is then used onthe specimens to detect the presence of adhesives, as the adhesives willfluoresce under this light. Other methods of detecting the presence ofadhesives may also be used. Areas of the specimens showing the presenceof adhesives are cut away from the specimens, such that the specimensare free of the adhesives. The specimens may now be tested using thespecific surface area method above.

Mass-Average Diameter

The mass-average diameter of fibers is calculated as follows:

$d_{mass} = {\frac{\sum\limits_{i = 1}^{n}\left( {m_{i} \cdot d_{i}} \right)}{\sum\limits_{i = 1}^{n}m_{i}} = {\frac{\sum\limits_{i = 1}^{n}\left( {\rho \cdot V_{i} \cdot d_{i}} \right)}{\sum\limits_{i = 1}^{n}\left( {\rho \cdot V_{i}} \right)} = {\frac{\sum\limits_{i = 1}^{n}\left( {\rho \cdot \frac{\pi\;{d_{i}^{2} \cdot {\partial x}}}{4} \cdot d_{i}} \right)}{\sum\limits_{i = 1}^{n}\left( {\rho \cdot \frac{\pi\;{d_{i}^{2} \cdot {\partial x}}}{4}} \right)} = \frac{\sum\limits_{i = 1}^{n}d_{i}^{3}}{\sum\limits_{i = 1}^{n}d_{i}^{2}}}}}$where

fibers in the sample are assumed to be circular/cylindrical,

d_(i)=measured diameter of the i^(th) fiber in the sample,

∂x=infinitesimal longitudinal section of fiber where its diameter ismeasured, same for all the fibers in the sample,

m_(i)=mass of the i^(th) fiber in the sample,

n=number of fibers whose diameter is measured in the sample

ρ=density of fibers in the sample, same for all the fibers in the sample

V_(i)=volume of the i^(th) fiber in the sample.

The mass-average fiber diameter should be reported in μm.

Gravimetric Weight Loss Test

The Gravimetric Weight Loss Test is used to determine the amount oflipid ester (e.g., GTS) in a nonwoven substrate of the presentdisclosure. One or more samples of the nonwoven substrate are placed,with the narrowest sample dimension no greater than 1 mm, into acetoneat a ratio of 1 g nonwoven substrate sample per 100 g of acetone using arefluxing flask system. First, the sample is weighed before being placedinto the reflux flask, and then the mixture of the sample and theacetone is heated to 60° C. for 20 hours. The sample is then removed andair dried for 60 minutes and a final weight of the sample is determined.The equation for calculating the weight percent lipid ester in thesample is:weight % lipid ester=([initial mass of the sample−final mass of thesample]/[initial mass of the sample])×100%.Absorption Capillary Potential and Desorption Capillary Potential

Absorption Capillary Potential, also referred to as absorption energy,and Desorption Capillary Potential, also referred to as desorptionenergy, can be determined by evaluating capillary work potential foreach tested material. The ability of absorbent materials to absorb ordesorb fluid via capillary potential is measure by the Capillary WorkPotential.

Equipment: A TRI Autoporosimeter from TRI, Princeton, N.J., is used tomeasure percentage of fluid saturation as a function of pressure of thesamples in Table 2 or any other sample for which data is desired. Testfluid is n-hexadecane.

There are three testing cycles to generate three capillary pressure vs.percent saturation curves: (1) 1st Absorption with dry material(imbibition); (2) Draining; and (3) 2nd Absorption with wet material.The Absorption Capillary Potential (absorption Capillary Work Potential(CWP)) is calculated by the integration of the 1st absorption curve ofcapillary potential as a function of uptake volume.

$W = {\int{P_{ca{p{({CV})}}}dC{V\left( \frac{mJ}{m^{2}} \right)}}}$

Where CV is the measured cumulative uptake volume (convertible tosaturation).

The Desorption Capillary Pressure (desorption Capillary Work Potential(CWP)) is calculated by the integration of the draining curve ofcapillary pressure as a function of uptake volume.

$W = {\int{P_{ca{p{({CV})}}}dC{V\left( \frac{mJ}{m^{2}} \right)}}}$

Where CV is the measured cumulative uptake volume (convertible tosaturation).

The extended capillary work potential (eCWP) is calculated as follows:

${Correction}\mspace{14mu}{Function}\frac{C\; W\;{P\left( \frac{mJ}{m^{2}} \right)}}{B\; W\;{T\left( \frac{g_{web}}{m^{2}} \right)}*{{Uptake}\left( \frac{g_{fluid}}{g_{web}} \right)}}$

Where CWP is the capillary work potential for the material/fluid system.BWT is the material basis weight and Uptake is the maximum fluid uptakeat full saturation, per gram of material.

Permeability (Darcy's) and Flow Rate (g/sec)

Permeability is determined from the mass flow rate of any given fluidthrough a porous medium. The procedure for determining both is asfollows:

Step 1: A through plane permeability device is used to automaticallydispense and measure flow of liquid through a sample by monitoring thedistance a column of water drops in relation to time and pressuremeasure.

Step 2: The pressure drop determines the mass flow rate of a fluidthrough a porous medium across the sample.

Step 3 (for flow rate of Table 2): The flow rate is determined atconstant pressure using the constant hydro head mode usingdistilled/de-ionized water as the fluid for all of the samples.

Step 4: Darcy permeability and Flow Rate is calculated by the equationsbelow:F=k*(A/μ)*(Δρ/l)K=9.87×10⁻¹³ *k

Where: F=flow Rate (g/s); k=permeability of the porous material (m²);A=Cross sectional area available for flow (m²); l=Thickness of thematerial (m); μ=Fluid viscosity (cP); Δp=Pressure Drop (cm H₂O); andK=permeability (Darcy's).

Free Gush Run-Off (Grams)

Handle all products without smoothing out wrinkles, pulling on, orpressing on the pad. Remove test product from all packaging includingFold & Wrap pouches. Allow all samples to equilibrate to the controlledroom temperature and humidity for at least two hours prior to testing.

-   1. For winged-products, remove the back sheet and pat a small amount    of corn starch onto the adhesive areas. This prevents the pad from    sticking to the incline. Use the adhesive on the wings to attach the    pad to the side of an incline. The incline shall be made of    plexiglass and angled at 15 degrees from a level horizontal plane.    The incline shall measure 30 cm long by 23 cm wide. (See FIG. 62,    item 7020).-   2. For non-winged products, remove the back sheet and use the    adhesive to attach to the incline.-   3. If the pad has a distinct front and back designation, orient the    pad on the incline so that the back of the pad is towards the bottom    of the incline.-   4. Place a small piece of double sided tape at the bottom of the    incline. Use this tape to secure the bottom of the pad.-   5. Place the pad on the incline so that the bottom of the pad lines    up with the bottom edge of the incline.-   6. The pad must be smooth and flat on the incline in the MD.-   7. Determine the geometric center of the pad being tested when    looking down on the topsheet of the pad. Mark the center with a    black felt tip pen. This marked center will be the assault point.    Fluid Assault Steps:-   1. Tare four 10-ml beakers. Using a disposable plastic pipette with    the tip cut off; load 3.0 g of AMF-B into each one of them. Pour    each of them back into the AMF-B reservoir. This primes the beakers    so that any fluid left is accounted for.-   2. Tare the four primed beakers from step 1. Load each beaker with    3.00±0.03 g of AMF-B.-   3. Place 5 layers of 5 in×5 in filter papers on balance and tare.    Place the stack at the bottom of the incline to capture any fluid    that runs off the incline.-   4. Set a timer for 1 minute, 10 seconds.-   5. Start the timer while simultaneously pouring one beaker of fluid    onto the assault point on the test pad. Ensure that this assault    takes place over 10±2 seconds. If the assault is shorter than eight    seconds or longer than 12 seconds, the test must be terminated. Do    not shake the beaker to dislodge the last drop of the fluid.-   6. When the timer sounds, three measurements must be made:    -   a. Run-Off: If there is any fluid that ran off the incline, it        is captured in the stack of tared filter papers at the bottom.        Reweigh the stack of filter paper to obtain the amount of fluid        run off. Record the weight to the nearest 0.01 g. If there is no        run off, record the weight as 0 g. Use the tared filter papers        to get the rewet weight below.-   7. Record data.-   8. Repeat steps 3-6 three more times immediately for a total of four    assaults recording data for each assault.-   9. Review/determine final data in accord with the below steps.    Run-Off: Amount of fluid that ran off and captured on the filter    paper at each assault is called Run Off. The total fluid that ran    off from all 4 assaults is also calculated. The average amount of    fluid that ran off at each assault for the replicate pads is also    calculated.    Trickle Test    1. Referring to FIG. 62, obtain a frame 7050 having multiple arms    which can support a first camera 7010, a second camera 7030, and a    delivery probe 7040. The first camera 7010 and second camera 7030    are Logitec C920 webcam or equivalent. The Delivery probe 7040 is an    18 gauge blunt end needle with luer fitting.    2. Program a syringe pump (KD Scientific Legato 100 infuse only    syringe pump or equivalent) to deliver fluid to the delivery probe    7040 at the following rate 0.33 ml/min for 3 minutes.    3. Fill the syringe pump with AMF—A    4. Connect the delivery probe 7040 to the syringe on the syringe    pump with PVC tubing having luer fitting ends.    5. Place a clean, standard chemistry beaker under the delivery    probe.    6. Purge air from the pump, tubing, and delivery probe by indexing    the pump.    7. Place a sample product on the incline 7020 such that the sample    is fully supported by the incline 7020. The sample should be placed    on the incline 7020 such that the length of the article is    positioned generally parallel to the length of the incline 7020. The    sample product is held by either adhesive backing on the pad sample    or a rubber band at either end of the sample which wraps around the    incline 7020.    8. Measure 90 mm from the leading edge (lower edge of the incline    7020) and mark the incline 7020 at this distance. Place a line    across the incline 7020 at this distance.    9. Place the incline 7020 with the sample thereon, under the    delivery probe 7040. The incline should be positioned under the    delivery probe 7040 such that the fluid from the delivery probe    strikes the incline 7020 at the line created in step 8.    10. Adjust the delivery probe 7040 to be 30 mm above the incline    7020 and centered along the width of the incline 7020.    11. Place a light box (box blocking out ambient light) over the    frame 7050 once the sample is placed on the incline 7020.    12. Attach the first camera 7010 and second camera 7030 to a    standard computer.    13. Initiate Logitech software or equivalent depending on webcam    supplier.    14. Center and zoom the first camera 7010 so that the sample is in    clear focus.    15. Focus the second camera 7030.    16. First camera 7010 and second camera 7030 should be focused such    that each can visually capture—clearly—the liquid insult striking    the sample and should be focused such that each camera clearly    captures liquid breaching the topsheet of the sample.    Sample Prep:    1. Obtain the sample.    2. Trim off any wings from the sample.    3. Cut the sample into thirds, each cut extending laterally across    the sample.    4. Identify the thirds of the sample that have formations which    resemble tufts and/or caps. Test these samples.    5. Position one of the samples to be tested on the incline 7020 such    that the probe is centered under the delivery probe 7040. If the    tufts/caps are offset from the center of the sample, then center the    delivery probe 7040 in the zone of tufts/caps nearest the center of    the sample.    Fluid Insult:    1. Set the delivery of fluid insult to be 0.33 ml/min for 3 minutes.    2. Count the number of drops of fluid which strike the sample before    the fluid breaches the topsheet.    Artificial Menstrual Fluid Preparation-A

For each of the tests using Artificial Menstrual Fluid-A (AMF-A),prepare as follows:

Step 1: Dilute 10 ml of reagent grade 85-95% w/w lactic acid to 100 mlwith distilled water. Label as 10% v/v lactic acid.

Step 2: Add 11.76 g of reagent grade 85% w/w potassium hydroxide (KOH)to a flask and dilute to 100 ml with distilled water. Mix untilcompletely dissolved. Label as 10% w/v KOH.

Step 3: Add 8.5 g sodium chloride and 1.38 g of hydrous monobasic sodiumphosphate to a flask and dilute to 1000 ml with distilled water. Mixuntil completely dissolved. Label as monobasic sodium phosphatesolution.

Step 4: Add 8.5 g sodium chloride and 1.42 g anhydrous dibasic sodiumphosphate to a flask and dilute to 1000 ml with distilled water. Mixuntil completely dissolved. Label as dibasic sodium phosphate solution.

Step 5: Add 450 ml of dibasic phosphate solution to a 1000 ml beaker andadd monobasic sodium phosphate solution until the PH is lowered to7.2±0.1. Label as phosphate solution.

Step 6: Mix 460 ml of phosphate solution and 7.5 ml of 10% KOH in a 1000ml beaker. Heat Solution to 45° C.±5° C. and then add 28 sterilizedgastric mucin (ICN Biomedical Inc., Cleveland, Ohio). Continue heatingfor 2.5 hours to completely dissolve the gastric mucin. Allow thesolution to cool to less than 40° C. and then add 1.8±0.2 ml of 10% v/vlactic acid solution. Autoclave the mixture at 121° C. for 15 minutes,then allow to cool to room temperature. Mucous mixture should be usedwithin 7 days. Label as gastric mucin solution.Step 7: Mix 500 ml of gastric mucin solution and 500 ml of fresh,sterile defibrinated sheep blood (Cleveland Scientific, AmericanBiomedical, Bath, Ohio) in a beaker. Label as artificial menstrualfluid. Store refrigerated and use within 7 days.Artificial Menstrual Fluid Preparation-BStep 1: Preparation of Phosphate Buffer Saline SolutionSolution A:

Taring the balance with each weighing dish, weigh out 1.40+/−0.05 g ofhydrous monobasic sodium phosphate and 8.50+/−0.05 g of sodium chloride.Record the weights in a lab notebook. Carefully, add the solids to a1000 ml volumetric flask and fill the flask about half way withdistilled water. Mix until completely dissolved. Bring the solution tovolume.

Solution B:

Taring the balance with each weighing dish, weigh out 1.40+/−0.05 g ofanhydrous dibasic sodium phosphate and 8.50+/−0.05 g of sodium chloride.Record the weights in a lab notebook. Add the solids to a 1000 mLvolumetric flask and fill about half way with distilled water. Mix untilthe solids are completely dissolved. Continue filling the flask withdistilled water until the bottom of the meniscus rests on the line inthe neck of the flask. Transfer to a plastic storage bottle and labelwith “Solution B”, the date, and your initials. Any unused solutionshould be discarded after 3 months.

PBS Solution: Combine 11 ml of solution A with 35 ml of solution B.

Step 2: Preparation of Gelatin

Measure about 100 g of distilled H₂O and bring to boil. Without cooling,weigh 80.8+0.1 g of the hot water in a 100 mL Pyrex bottle with a screwcap. Weigh 4.20+0.05 g of unflavored gelatin in a weigh boat. Add it tothe hot water slowly while mixing with a stir bar. Mix until dissolved.Dissolution can take up to 2 h. Place in refrigerator and refrigerate atleast overnight. This concentration of gelatin allows the gelatin to bemore rigid at room temperature. Expires in one week.

Step 3. Preparation of 1% Superfloc 150 in 1% NaCl Solution

Boil about 130 ml of distilled water for 5 min to sterilize. No need tocool before proceeding to next step. Weigh 99 g of hot water and add1.00±0.05 g of NaCl into a 250 mL beaker. Stir to dissolve completely.Transfer 99 g of above 1% NaCl solution to a 250-mL Pyrex bottle with ascrew cap. Weigh 1.00±0.01 g of Superfloc 150 on a weigh boat andtransfer to the 250 mL bottle. Invert the bottle several times to mix.The bottle must be inverted several times a day for up to a week tofully hydrate. The fluid must be a single phase, free from gel-like,hazy phase before it can be used. It takes up to a week to fully hydratethe Superfloc. Prepare this solution well before the previous stock isexhausted. Use until finished or within 3 months. Do not use ifcloudiness exists which is an indication of bacterial growth.

Step 4: AMF-B Preparation

To Make 500 g:

Use a Pyrex bottle with a screw cap. Weigh out 35.00±0.05 g of thegelatin gel and add it to 107.5±0.05 g of PBS solution. Warm the mixtureto 30-35 C to melt the gelatin. Once it is melted, let it cool down to25 C and then add the 7.50±0.05 g of the 1% Superfloc 150 solution. Mixwell by inverting several times. Add 350.0±0.1 g of sheep blood that isat 25 C. Mix well by inverting. Do not use a stirrer.

-   -   35.00 g gelatin    -   107.50 g PBS solution    -   7.50 g of 1% Superfloc 150 solution    -   350.0 g Sheep blood        To Make 200 g:

Use the weights of ingredients listed below in the same way as describedin making 500 g sample.

-   -   14.00 g gelatin    -   43.0 g PBS solution    -   3.0 g of 1% Superfloc 150 solution    -   140.0 g Sheep blood

Measure and record the stringiness using a Ryometer as described below.The stringiness does not change with age of the fluid. It need not bemeasured again. Place the prepared AMF-B in refrigerator overnight. Itsviscosity must be tested before each use as described below.

Fluid Testing (Viscosity/stringiness)

Viscosity Measurement

-   -   Bring the temperature of the AMF-B to room temperature (25        degrees C.) by placing it in a warm water bath. The temperature        of the water bath must be 35-40 degrees C. Do not stir or        vigorously shake the bottle. Gently mix the solution before        taking a sample to measure.

Measure the viscosity of each batch of artificial menses before use eachday using an AR 2000 Rheometer or equivalent. These instructions are forthe AR2000 Rheometer.

-   -   1. Turn on instrument, check cooling water level and make sure        water is circulating into the reservoir.    -   2. Install the upper plate by holding the knob on top and        screwing the plate on. Be careful that the top portion is steady        since air bearings can be damaged easily.    -   3. Once plate is in place spin gently.    -   4. Move computer mouse to activate screen. Double click on        instrument control icon.    -   5. Check temperature on sheet and instrument display, it should        read 25 degrees C.    -   6. Run zero gap by hitting the zero gap icon. Follow        instructions.    -   7. At least once per week, or if the plate has been removed,        perform instrument rotational mapping.    -   8. Make folder for the data by dates tests are run. File/new        file/daily.    -   9. Change name by highlighting the sample name and change the        information then select browse to put the file in the proper        folder.    -   10. Run Standard (S60) at least once a month—be sure to change        the density.    -   11. With an Eppendorf pipette set at 1 ml with wide mouth        pipette tip pull up AMF-B with no air bubbles by priming a        couple times. Dispel sample on the platform without any bubbles        and then lower the upper plate to the point where the plate        touches the fluid. Turn the spindle a little without spinning.    -   12. Go to enter gap icon and decrease the distance until the        fluid is parallel to the edge of plate. Manually turn the        spindle so the fluid is evenly distributed under the plate.    -   13. If fluid comes out past the edge of the plate wipe off        excess fluid—always hold top knob when wiping plate.    -   14. The gap should be within a range of 700-900 um range and        then that gap needs to be entered under the 40 mm steel plate        dimension under gap.    -   15. Place the cover over the plate.    -   16. The shear rate scan procedure is named Geoff's Procedure.        This procedure makes a series of steady-state viscosity        measurements from 0.01 to 30 sec⁻¹ and usually takes 20 minutes        to complete. The oscillatory (structure measurement) and shear        rate scan combined procedure is listed as Geoff's procedure.    -   17. Press the green triangle to start to run.    -   18. Once the procedure is done then the data needs to be        analyzed using the Data Analysis Icon.    -   19. Pull up data and send to graph for analysis. You can pull up        actual data by selecting the spreadsheet picture grid.    -   20. The AMF-B should be shear thinning and at 20 sec⁻¹ the        viscosity should be 20.0±3.0 cP at 25 C. Viscosity at a shear        rate of 20 sec⁻¹ was selected for its relevance to shear        experienced by the fluid during gush acquisition events.    -   21. If AMF-B viscosity is too high (greater than 23.0 cP at 20        sec⁻¹), it can be brought down by adding some PBS buffer. The        volume of the PBS buffer added should not exceed 10% of the        total volume. For e.g., for a 500 ml AMF-B sample, do not add        more than 50 ml of PBS buffer to get viscosity in the required        range.    -   22. If the viscosity is too low (less than 17.0 cP at 20 sec⁻¹),        discard the fluid or place the fluid back into the refrigerator        for at least another 24 hours.        CLEAN UP—Wear latex/nitrile gloves, raise plate, wet with water        a paper towel that is folded into quarters, wipe plate and        platform making sure to hold knob while cleaning plate. Follow        the water with alcohol wipe and drying.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An article comprising: a chassis having atopsheet, a backsheet, and an absorbent core disposed between thetopsheet and the backsheet; and an elastic ear comprising: a first layercomprising a nonwoven web, wherein the nonwoven web comprises: a firstplurality of continuous fibers having a hydrophilic melt additive, and asecond plurality of continuous fibers having a hydrophobic meltadditive; and a second layer comprising a film; wherein the first layerand the second layer are joined together by ultrasonic bonding; whereinthe second layer comprises a plurality of apertures, and a portion ofthe first layer is exposed through at least one of the plurality ofapertures, and wherein the first layer comprises a plurality ofapertures, and a portion of the second layer is exposed through at leastone of the plurality of apertures.
 2. The article of claim 1, whereinthe nonwoven web comprises a crimped fiber spunbond nonwoven web.
 3. Thearticle of claim 2, wherein the crimped fiber spunbond nonwoven web islocated on a garment-facing surface of the elastic ear.
 4. The articleof claim 2, wherein the crimped fiber spunbond nonwoven web comprisesfibers having two different polypropylene polymers configured in aside-by-side configuration.
 5. The article of claim 1, furthercomprising an additional layer comprising continuous spunbond crimpedfibers.
 6. The article of claim 1, wherein the first layer comprises ameltblown web.
 7. The article of claim 1, wherein the elastic ear isdisposed in the rear waist region.
 8. The article of claim 1, furthercomprising a fastening system joined to the elastic ear.
 9. The articleof claim 1, wherein the elastic ear is integral with the chassis. 10.The article of claim 1, wherein the elastic ear is a separate componentfrom the chassis.
 11. An article comprising: a chassis having atopsheet, a backsheet, and an absorbent core disposed between thetopsheet and the backsheet; and an elastic ear comprising: a laminatehaving layers joined together with a plurality of ultrasonic bonds, thelayers comprising nonwoven web layers and a film layer; wherein at leastone of the nonwoven web layers comprises a crimped fiber spunbondnonwoven web comprising: a first plurality of continuous fibers having ahydrophilic melt additive, and a second plurality of continuous fibershaving a hydrophobic melt additive; and wherein at least two of thelayers comprises a plurality of apertures, and a portion of at leastanother one of the layers is exposed through at least one of theplurality of apertures.
 12. The article of claim 11, wherein the crimpedfiber spunbond nonwoven web comprises fibers having two differentpolypropylene polymers configured in a side-by-side configuration. 13.The article of claim 11, wherein the at least one of the nonwoven weblayers comprises a meltblown web.
 14. The article of claim 11, whereinthe elastic ear is disposed in the rear waist region.
 15. The article ofclaim 11, further comprising a fastening system joined to the elasticear.